Helmet

Abstract

A helmet (1) comprising: at least one cellular energy absorbing insert (2); a foam liner (3) comprising at least one recess (4) shaped to receive the at least one cellular energy absorbing insert (2); a cover layer (5) arranged between the foam liner (3) and the at least one cellular energy absorbing insert (2); wherein the cover layer (5) is attached to the at least one honeycomb energy absorbing insert (2) such that the honeycomb energy absorbing insert (2) slides over the foam liner (3) together with the cover layer (5) in response to an oblique impact.

Description

Technical Field

[0001] This invention relates to the field of helmets with honeycomb energy-absorbing structures. Specifically, this invention relates to helmets using layered structures. Background Technology

[0002] In the prior art, several helmet solutions using honeycomb energy-absorbing structures are known. These structures exhibit superior impact energy absorption performance compared to conventional polymer foam materials. Nevertheless, foam allows for attractive shapes and is still easier to mold than honeycomb structures. Therefore, many solutions employing this energy-absorbing structure combine a foam liner with a honeycomb structure.

[0003] An example in this sense is disclosed in patent US10834987. This document relates to a helmet comprising multiple honeycomb liners held within corresponding grooves in a polymer foam shell without the need for additional fasteners or adhesives. Essentially, the honeycomb liners in this document are sized to fit snugly within the grooves. Although the honeycomb liners are held within the foam shell, during an oblique impact to the helmet, they tend to slide over the barrier layer attached to the polymer shell, while simultaneously compressing in-plane. In severe impacts, the thin edges of the honeycomb liners facing the foam liner and barrier layer will scrape against the barrier layer, creating friction and significantly reducing the tendency for the honeycomb liners to slide over the barrier layer, thus increasing the risk of head twisting (torque). This defect becomes more pronounced if the honeycomb liners are located below or behind the vents of the foam liner. During an impact, the honeycomb liner tends to slide over the barrier layer, but when the edges of the honeycomb liner cross the vent, they get stuck in the vent, and the sliding is abruptly interrupted, which has a serious impact on safety.

[0004] Patent EP3473122B1 partially solves this problem by using a chamfered vent that allows the energy-absorbing insert in the bicycle helmet to not stop in the vent and to slide under limited constraints.

[0005] Furthermore, US10736373B2 relates to a helmet solution in which a foam liner is shaped to hold one or more honeycomb inserts within the foam liner. The foam liner of this helmet includes vents that allow air to reach the honeycomb liner and pass through it to the cavity containing the wearer's head. If the helmet is a ski helmet, the ambient air entering the helmet can be too cold, causing the head temperature to drop rapidly. To avoid this inconvenience, it is known to use visors that open and close the vents, but this solution is both uneconomical and risky because the visor could be an object reaching the head upon impact, or at best, a potential point of breakage for the helmet upon impact. An alternative solution could be to reduce the cross-section of the vents, but this solution presents problems during molding because the inserts used to create these small vents become too thin and risk rupture when the mold is opened to remove the molded foam liner. Summary of the Invention

[0006] The aforementioned disadvantages and other drawbacks of the prior art are now addressed by a helmet comprising: at least one honeycomb energy-absorbing insert; a foam liner including at least one recess shaped to accommodate the at least one honeycomb energy-absorbing insert; and a cover layer disposed between the foam liner and the at least one honeycomb energy-absorbing insert. The cover layer is attached to the at least one honeycomb energy-absorbing insert such that the honeycomb energy-absorbing insert slides on the foam liner together with the cover layer in response to an oblique impact. The cover layer makes the honeycomb energy-absorbing insert smoother, with less friction and roughness. In this way, the honeycomb energy-absorbing insert slides on the foam liner without getting stuck. Furthermore, despite the presence of vents, the cover layer still allows the honeycomb energy-absorbing insert to slide on the foam liner.

[0007] Preferably, the cover layer can be made of an elastic material. In this way, the cover layer can easily adapt to any in-plane compression of the honeycomb energy-absorbing insert.

[0008] Advantageously, the overlay can be made of fabric. In this way, the overlay allows air to pass through it and is easily adaptable to any modification to the shape of the honeycomb energy-absorbing insert, especially if it is elastic.

[0009] The overlay can be breathable. This allows air to pass through the overlay in a restricted manner, compared to the uncovered honeycomb energy-absorbing insert. This feature makes the ski helmet warmer and more comfortable.

[0010] Preferably, the overlay can be opaque. In this way, the honeycomb energy-absorbing insert is not visible from the outside through the vent. Furthermore, the opaque overlay allows for the personalization of the honeycomb energy-absorbing insert's appearance using specific colors or patterns.

[0011] Specifically, if the helmet includes an outer shell, the overlay and the outer shell can be the same color. In this way, the honeycomb energy-absorbing insert is not visible and remains camouflaged along with the helmet's outer shell.

[0012] Advantageously, the honeycomb energy-absorbing insert may comprise multiple interconnected open cells configured to absorb energy through plastic deformation in response to longitudinal compressive loads applied to the cells. This type of honeycomb material offers excellent results in energy absorption and is very lightweight.

[0013] Specifically, each unit may include a tube having one or more sidewalls and a longitudinal axis, and the units are connected to each other through their sidewalls. This feature enables the production of sheets of interconnected side-by-side units.

[0014] Preferably, the cover layer can be attached to the open end of the open cell. This attachment between the cell and the cover layer ensures maximum flexibility in the deformation of the honeycomb insert, because the cover layer does not restrict the honeycomb energy-absorbing insert.

[0015] Advantageously, the helmet may include a protective layer attached to the foam liner corresponding to one or more bottoms of the one or more recesses. This protective layer facilitates relative sliding of the honeycomb energy-absorbing insert over the foam liner and prevents the honeycomb energy-absorbing insert from sinking into the foam liner. The protective layer can enhance the effectiveness of the overlay.

[0016] Specifically, the protective layer may also be attached to one or more sidewalls of the one or more recesses. In this way, it is easy to insert / remove the honeycomb energy-absorbing insert, even during assembly or disassembly.

[0017] Preferably, the protective layer can be a coating or film applied over the recess in the foam liner. In this way, the coating can be sprayed onto one or more inner surfaces of the recess. Alternatively, the film can be easily attached to the bottom of the recess, for example, with an adhesive.

[0018] Advantageously, the honeycomb energy-absorbing insert can possess a cynical property. This feature allows the honeycomb energy-absorbing insert to deform spherically without distorting the cells. In this way, the honeycomb energy-absorbing insert can be realized as a flat sheet, which is then bent and inserted into the recess.

[0019] Preferably, compared to a foam liner, a honeycomb energy-absorbing insert can be configured to provide better shock absorption protection. The honeycomb energy-absorbing insert has better energy absorption performance than a foam liner. Furthermore, because it is independent of the foam liner, the honeycomb energy-absorbing insert can be placed in specific areas of the helmet to improve protection for certain parts of the wearer's head.

[0020] Specifically, the foam liner can be made of polymer expanded foam. This material makes the foam liner easy to manufacture and mold.

[0021] The foam liner may include vents through which air can pass. The vents allow air to travel from the outside of the helmet into the cavity containing the wearer's head.

[0022] These and other advantages will be better understood in the following description of different embodiments of the invention given with reference to the accompanying drawings as non-limiting examples. Attached Figure Description

[0023] In the attached diagram: Figure 1 A schematic cross-sectional view of a helmet according to a first embodiment of the present invention is shown; Figure 2 A schematic cross-sectional view of a helmet according to a second embodiment of the present invention is shown; Figure 3 It shows Figure 1 The state of the helmet during the oblique impact; Figure 4 It shows Figure 2 The state of the helmet during the oblique impact; Figure 5 A partial schematic cross-sectional view is shown showing the interaction between the foam liner and the honeycomb energy-absorbing insert of the helmets of the first and second embodiments during impact; Figure 6 A schematic cross-sectional view of a helmet according to a third embodiment of the present invention is shown; Figure 7 A schematic cross-sectional view of a helmet according to a fourth embodiment of the present invention is shown; Figure 8 It shows Figure 6 The state of the helmet during the oblique impact; Figure 9 It shows Figure 7 The state of the helmet during the oblique impact; Figure 10 A partial schematic cross-sectional view is shown showing the interaction between the foam liner and the honeycomb energy-absorbing insert of the helmets of the third and fourth embodiments during impact; Figure 11An isometric view of a first type of honeycomb energy-absorbing insert with a covering layer is shown; Figure 12 An isometric view of a second type of honeycomb energy-absorbing insert with a covering layer is shown. Detailed Implementation

[0024] The following description of one or more embodiments of the present invention refers to the accompanying drawings. The same reference numerals indicate the same or similar parts. The object of protection is defined by the appended claims. The technical details, structures, or features of the solutions described below can be combined with each other in any suitable manner.

[0025] In the following text, the term "honeycomb energy absorption insert" may be abbreviated to the term "honeycomb insert".

[0026] Reference numeral 1 in the figure indicates a helmet according to the present invention.

[0027] The helmet 1 includes an outer foam liner 3, preferably made of polymer expanded foam such as EPS or EPP. The helmet 1 also includes one or more honeycomb inserts 2 disposed in corresponding recesses 4 within the foam liner 3. Figure 1 In the first embodiment shown, the helmet 1 includes more honeycomb inserts 2, while Figure 2 In the second embodiment depicted, the helmet 1 includes a honeycomb insert 2.

[0028] The terms “outer” and “inner” refer to the ideal orientation starting from the cavity 13 of the helmet 1, in which the wearer’s head can be placed on the outer side of the helmet 1.

[0029] Each recess 4 is shaped to accommodate a corresponding honeycomb insert 2. To achieve this, the outer portion of the honeycomb insert 2 is larger than the inner portion, and the opening of the recess 4 is narrower than the bottom. Furthermore, the shape of the recess 4 is substantially complementary to the shape of the corresponding honeycomb insert 2, such as... Figure 1 , 2 As shown in numbers 3, 4, 6, 7, 8, and 9.

[0030] The outer surface of each honeycomb insert 2 is covered by a covering layer 5, so that when the honeycomb insert 2 is arranged in one or more recesses 4 of the foam liner 3, the covering layer 5 remains between the foam liner 3 and the honeycomb insert 2. Figure 1 , 2 As shown in numbers 3, 4, 6, 7, 8, and 9.

[0031] In all embodiments, the cover layer 5 can be made of an elastic material to follow the deformation of the honeycomb insert 2, especially during impact. Indeed, when an oblique impact occurs, the honeycomb insert 2 undergoes in-plane compression, such as... Figure 3, 4 As shown in Figures 8 and 9, the cover layer 5 will deform unhindered by the honeycomb insert 2. In this case, the resilient cover layer 5 may include small perforations to allow air to pass through it. The perforations may be small enough to conceal the honeycomb insert 2 while still allowing for permeability.

[0032] The covering layer 5 is attached to the outer surface of the honeycomb insert 2.

[0033] Preferably, the covering layer 5 can be made of woven or breathable fabric to allow air to pass through it. Even though the airflow through the fabric is reduced compared to the airflow that could pass through the honeycomb insert 2 without the fabric, the covering layer made of fabric is indeed breathable.

[0034] Preferably, the cover layer 5 is made of elastic fabric to achieve controlled permeability and follow the deformation of the honeycomb insert 2.

[0035] Alternatively, the covering layer 5 can be a piece of inelastic fabric.

[0036] The fabric overlay 5 is also waterproof and breathable. This way, the helmet stays dry even in rainy weather. An example of waterproof and breathable fabric is...

[0037] The permeability of the covering layer 5 made of fabric can be increased or decreased by enlarging or restricting the mesh size of the fabric.

[0038] Alternatively, the covering layer 5 can be impermeable to prevent air from passing through it.

[0039] The honeycomb insert 2 includes a honeycomb energy-absorbing material that performs better than traditional foam materials in terms of shock absorption, especially in absorbing compressive impact energy.

[0040] The honeycomb insert 2 is made of multiple interconnected open units 7. These units 7 are configured to absorb energy through plastic deformation in response to longitudinal compressive loads, thereby absorbing out-of-plane compression.

[0041] Each unit 7 forms a tube with sidewalls and a longitudinal axis. Airflow can pass through each unit 7 in a direction parallel to the longitudinal axis.

[0042] Units 7 are interconnected via their sidewalls 8. Adhesive can hold the units 7 together. Units 7 can be welded to each other by partially melting their sidewalls 8. Alternatively, units 7 can be bonded by means of an adhesive layer (not shown) inserted between adjacent sidewalls 8.

[0043] The honeycomb insert 2 can be implemented from a flat sheet of interconnected cells 7 that are subsequently bent. For example... Figure 11 , 12 As shown, the flat sheet of unit 7 resembles a floor tile / brick of interconnected units 7 with parallel longitudinal axes. To obtain the shape of the honeycomb insert 2, the flat sheet is first cut to a specific shape and then bent. The flat sheet typically has a constant thickness.

[0044] If the flat sheet of unit 7 has unidirectional curved properties, it can be bent by thermoforming or manually. Therefore, Figure 11 , 12 The flat sheet of Unit 7 can be in the shape of a single curve or a hyperbola.

[0045] Unit 7 can be a cylindrical tube, such as Figure 12 As shown. Figure 12 The tube depicted has a circular cross-section. Alternatively, unit 7 may include sidewalls 8 bonded together to form tubes of other shapes. Specifically, the cross-section of unit / tube 7 may be square, hexagonal, non-uniform hexagonal, concave hexagonal, chiral truss, rhombus, or triangular.

[0046] exist Figure 11 In the example, unit 7 has an arrow shape. This shape of unit 7 exhibits unidirectional curved surface characteristics. Therefore, unit 7 can be spherically bent without thermoforming.

[0047] The thickness of the sheet used to obtain the honeycomb insert 2 can be between 15 mm and 40 mm.

[0048] When unit 7 has a circular cross-section, the outer diameter of the circular cross-section can be between 2.5 mm and 8 mm, and the wall thickness of unit 7 can be between 0.05 mm and 0.3 mm. Based on these dimensional values, the energy absorption and weight of unit insert 2 are optimized.

[0049] The cover layer 5 is attached to the top edge 9 of the open cell 7 of the honeycomb insert 2.

[0050] The covering layer 5 can be attached to these edges 9 via a heat-activated adhesive. The heat-activated adhesive can be a thermosetting polyester web adhesive.

[0051] The main advantage of the cover layer 5 is that it improves the sliding of the honeycomb insert 2 within the recess 4 of the foam liner 3. Specifically, the cover layer 5 prevents the honeycomb insert 2 from stopping in the vent 6 during oblique impacts. Even when a perforated load is applied, the cover layer 5 has the additional effect of distributing impact energy to more cells 7.

[0052] Figure 11 , 12Two types of honeycomb inserts 2 are shown, wherein a cover layer 5 is attached to the honeycomb insert 2. Figure 11 In the image, viewed from the bottom, the honeycomb insert 2 has a cover layer 5 located behind it. The top edge 9 of the unit 7 is attached to the cover layer 5. Figure 12 In the middle, the honeycomb insert 2 is viewed from the side, so the top surface of the cover layer 5 can be seen.

[0053] exist Figure 11 , 12 In this helmet, the covering layer 5 is a densely woven fabric through which the honeycomb insert 2 can be seen. The density of the fabric can be even greater to completely cover the honeycomb insert 2. In this way, the covering layer 5 is opaque, and the honeycomb insert 2 cannot be seen through the covering layer 5. Therefore, when observing the helmet 1 from the outside, the honeycomb insert 2 cannot be seen through the vent 6.

[0054] In this case, the cover layer 5 has slight permeability and can be used in ski helmets that require less permeability.

[0055] Overlay 5 can also be colored or graphic-customized to provide a personalized visual effect.

[0056] When the helmet 1 includes the outer shell 12, the outer shell 12 and the cover 5 can have the same color or pattern, so that the helmet 1 appears to have no vents 6 when viewed from the outside.

[0057] Figure 8 and Figure 9 The third and fourth embodiments and Figure 1 and Figure 2 The difference between the first and second embodiments is the presence of a protective layer 10.

[0058] The protective layer 10 may be a thin film attached to or otherwise laminated to the bottom of the recess 4, such as Figure 8 As shown. Alternatively, the protective layer 10 may be a coating applied by spraying or otherwise distributing onto the inner surface of the recess 4, such as... Figure 9 As shown. In the latter case, the protective layer 10 covers both the bottom and the sidewall 11 of the recess 4.

[0059] All other features of the first and second embodiments are consistent with those of the third and fourth embodiments, respectively.

[0060] Figure 3 , 4 Helmets of the first and second embodiments are shown when an oblique impact occurs. The term "oblique impact" refers to an impact that includes both normal and tangential components, such as... Figure 3 , 4 As shown in Figures 8 and 9. The terms "normal" and "tangential" are used with reference to the outer surface of helmet 1.

[0061] The outer surface of helmet 1 may be covered with an outer shell 12, such as Figure 1 , 2 As shown in 3, 4, 6, 7, 8, and 9. Alternatively, the outer surface of helmet 1 does not have an outer shell 12. The outer shell 12 can also be rigid or flexible, depending on the ultimate purpose of helmet 1.

[0062] When helmet 1 impacts an object, helmet 1 will experience a load, such as Figure 3 , 4 As indicated by arrows and reference numeral "F" in figures 8 and 9, the load F tends to rotate the helmet 1 and the wearer's head, which is attached to the helmet 1 by a retaining system (not shown). Nevertheless, due to the cover layer 5, the honeycomb insert 2 can slide over the foam liner 3 or over the protective layer 10 attached to the foam liner 3. Thus, a portion of the helmet 1 rotates under the load F, while the honeycomb insert 2 undergoes in-plane compression, absorbing the tangential component of the load F and transferring less impact energy to the wearer's head. During this in-plane compression, the cover layer 5 deforms following the honeycomb insert 2 as it is attached to the cell 7 of the honeycomb insert 2.

[0063] If the covering layer 5 is elastic or elastic fabric, no wrinkles will appear on the honeycomb insert 2 that has been compressed in the plane.

[0064] like Figure 5 and Figure 10 As shown, except Figure 10 There is a protective layer 10 in the middle, Figure 5 and Figure 10 Equivalently, the honeycomb insert 2 and its covering layer 5 move relative to the foam liner 3. Specifically, due to the covering layer 5, the honeycomb insert 2 slides on the foam liner 3, or on the protective layer 10 attached to the foam liner 3, without entering or blocking the vent 6.

[0065] All helmets in all embodiments of the present invention include a vent 6 in the foam liner 3. If an outer shell 12 is present, the vent 6 also extends through the outer shell 12.

[0066] Vents 6 may or may not correspond to one or more recesses 4. If some vents 6 are provided corresponding to each other, the cover layer 5 may be permeable or impermeable, depending on the end purpose of the helmet 1. For example, if the helmet 1 is a ski helmet, it is preferable that the cover layer 5 has low permeability.

[0067] The helmet 1 may also include vents located outside the periphery of one or more recesses 4 (not shown). In this case, these vents 6 extend from the outer surface of the helmet 1 to the inner surface.

[0068] Once a small or large amount of air passes through the covering layer 5, the air can flow freely through the cells 7 of the honeycomb insert 3 and reach the cavity 13 in which the head is arranged.

[0069] In summary, the present invention is readily conceived to be modified and varied in many ways, all of which fall within the scope of the invention's concept. Furthermore, all features can be replaced by technically equivalent alternatives. In fact, the number can vary depending on specific technical requirements. Finally, all features of the previously described embodiments can be combined in any way to obtain other embodiments not described herein for practical and clear reasons. List of reference numerals 1 Helmet 2. Honeycomb-shaped energy absorption insert 3. Foam lining 4 concavity 5. Covering layer 6 Vents Unit 7 8 (unit) sidewalls 9 (unit) edge 10 protective layers 11 (The side wall of the concave part) 12 outer shell 13. Cavities (for the wearer's head)

Claims

1. A helmet (1), comprising: - At least one honeycomb-shaped energy absorption insert (2); - Foam liner (3), the foam liner including at least one recess (4), the recess being shaped to receive the at least one honeycomb energy absorption insert (2); - Covering layer (5), the covering layer being disposed between the foam liner (3) and the at least one honeycomb energy absorption insert (2); The cover layer (5) is attached to the at least one honeycomb energy-absorbing insert (2) such that the honeycomb energy-absorbing insert (2) slides together with the cover layer (5) on the foam liner (3) in response to an oblique impact.

2. The helmet (1) according to claim 1, characterized in that, The covering layer (5) is made of an elastic material.

3. The helmet (1) according to claim 1 or 2, characterized in that, The covering layer (5) is made of fabric.

4. The helmet (1) according to any one of the preceding claims, characterized in that, The covering layer (5) is breathable.

5. The helmet (1) according to any one of the preceding claims, characterized in that, The covering layer (5) is opaque.

6. The helmet (1) according to any one of the preceding claims, characterized in that, Includes an outer shell (12), wherein the covering layer (5) and the outer shell (12) have the same color.

7. The helmet (1) according to any one of the preceding claims, characterized in that, The honeycomb energy-absorbing insert (2) includes a plurality of interconnected open units (7) configured to absorb energy through plastic deformation in response to a longitudinal compressive load applied to the unit (7).

8. The helmet (1) according to claim 7, characterized in that, Each unit (7) includes a tube having one or more sidewalls (8) and a longitudinal axis, and the units (7) are connected to each other through their sidewalls (8).

9. The helmet (1) according to claim 7 or 8, characterized in that, The cover layer (5) is attached to the open end (9) of the open unit (7).

10. The helmet (1) according to any one of the preceding claims, characterized in that, It also includes a protective layer (10) that is attached to the foam liner (3) corresponding to one or more bottoms of the one or more recesses (4).

11. The helmet (1) according to claim 10, characterized in that, The protective layer (10) is also attached to one or more sidewalls (11) of the one or more recesses (4).

12. The helmet (1) according to claim 10 or 11, characterized in that, The protective layer (10) is a coating or film applied over the recess (4) of the foam liner (3).

13. The helmet (1) according to any one of the preceding claims, characterized in that, The honeycomb-shaped energy absorption insert (2) has curved surface unidirectionality.

14. The helmet (1) according to any one of the preceding claims, characterized in that, Compared to the foam liner (3), the honeycomb energy-absorbing insert (2) is configured to provide improved vibration absorption protection.

15. The helmet (1) according to any one of the preceding claims, characterized in that, The foam liner (3) includes a vent (6) through which air can be transmitted.

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