Helmet and method for assembling a helmet

Abstract

A helmet (1) for protecting a wearer's head comprising an energy absorbing layer (2) configured to absorb energy at impact on the helmet (1), a substantially rigid outer shell (3) configured to at least partly engage and cover an outer surface of the energy absorbing layer (2), and a mechanical connector element (4, 5) configured to mechanically attach said outer shell (3) to the energy absorbing layer (2).

Description

HELMET AND METHOD FOR ASSEMBLING A HELMETField of the Invention

[0001] The present invention generally relates to a helmet, in particular for sports, more in particular for cycling, and a method for assembling said helmet.Background of the Invention

[0002] Helmets for protecting a wearer’s head are well known and generally used in a variety of sports such as cycling, horse riding, climbing, skiing and other sports. Such helmets generally comprise an energy absorbing layer configured to at least partly absorb a shock of an impact. Said energy absorbing layer can be relatively thick and may for example be made of expanded polystyrene (EPS). The helmets further comprise an outer shell at least partly covering said energy absorbing layer. Said outer shell may be relatively thin and light-weight and is generally made of a substantially rigid material, such as for example carbon fibre, polycarbonate or ABS. The outer shell can be glued to the energy absorbing layer, or the energy absorbing layer and the outer shell can be chemically bonded, for example by inmoulding, which is a generally known but relatively difficult process for manufacturing helmets.

[0003] In both cases, when helmets come to an end of their lifetime, the outer shell and the energy absorbing layer will be relatively difficult to separate, either due to the glue used between the outer shell and the energy absorbing layer, or due to the inmoulding. As a result, recycling of helmets, in particular of the different materials of the helmet, has shown to be hardly possible, since recycling requires a relatively good separation of different materials of a product. However, there is a growing demand for recyclable helmets.

[0004] At the same time, helmets for protecting a wearer’s head need to satisfy relatively strict safety requirements to be allowed on the market. Said safety requirements may differ from one sport to another, but generally include requirements which prevent replacement of components because such a replacement might hampergeneral safety of the helmet. Helmet components should therefore be attached in a way to prevent tampering.

[0005] It is therefore an aim of the present invention to solve or at least alleviate one or more of the above-mentioned problems. In particular, the invention aims at providing a safe helmet and a method for assembling said helmet allowing the helmet to be at least partially recyclable while keeping up high standards in head protection.Summary of the Invention

[0006] To this aim, according to a first aspect of the invention, there is provided a helmet having the features of claim 1 . In particular, the helmet for protecting a wearer’s head comprises an energy absorbing layer configured to absorb energy at impact on the helmet and a substantially rigid outer shell configured to at least partly engage and cover an outer surface of the energy absorbing layer. The substantially rigid outer shell preferably directly engages the energy absorbing layer, without any intermediate layers in between the substantially rigid outer shell and the energy absorbing layer. Contrary to prior art helmets, the substantially rigid outer shell is not glued on the energy absorbing layer. Instead, the helmet further comprises a mechanical connector element configured to mechanically attach said outer shell to the energy absorbing layer. The mechanical connector element is configured to allow a substantially permanent, fixed and adhesive-free engagement between said substantially rigid outer shell and said energy-absorbing layer. The permanent engagement or attachment of the substantially rigid outer shell on the energy absorbing layer is to be understood as non-replaceable during the lifetime of the helmet and not configured to detach at impact on the helmet. In other words, the attachment is not a releasable attachment. This is to prevent the possibility of tampering on the helmet, which may negatively influence a safety level of the helmet. The fixed engagement or attachment is to be understood as an engagement which is configured to prevent or not to allow a sliding movement of the substantially rigid outer shell over the energy absorbing layer, for example on impact on the helmet. In other words, the engagement is configured to prevent any movement between the substantially rigid outer shell and the energy absorbing layer such that the position of the substantially outer shell on the energy absorbing layer isfixed. Finally, the engagement or attachment of the substantially rigid outer shell on the energy absorbing layer is an adhesive-free or glueless engagement, i.e. free of any kind of adhesive, glue or chemical bonding. Thanks to such a mechanical connector element allowing a substantially permanent, fixed and adhesive-free engagement between said substantially rigid outer shell and said energy-absorbing layer, the invention can provide a safe helmet allowing the helmet to be at least partially recyclable when the helmet has been dumped. Only at the end of the lifetime of the helmet, or when the helmet is not used anymore, can the helmet be separated relatively easily into components of substantially a same material to simplify recycling of said components. In particular, thanks to the mechanical connector element and the mechanical attachment of the substantially rigid outer shell on the energy absorbing layer, the substantially rigid outer shell can be separated from the energy absorbing layer for recycling purposes since none of these components include any trace of glue, which would seriously complicate recycling. The possibility of disassembling the helmet at an end of a helmet’s lifetime is not in contradiction with the permanent nature of the engagement. The permanent engagement is referring to a period or time of use of the helmet before being dumped, and is opposed to releasable engagements, as previously explained.

[0007] The mechanical connector element may be configured to at least slightly damage the energy absorbing layer and / or the substantially rigid outer shell, and / or may be configured to get damaged itself when the helmet is disassembled. In this way, the damage can prevent a user from trying to use the mechanical connector element as a releasable element, providing a substantially permanent character to the attachment of the substantially rigid outer shell on the energy absorbing layer. As a result, the helmet may be protected against tampering.

[0008] The mechanical connector element can advantageously be positioned such that a thickness of the energy absorbing layer is at least 3 mm radially at the location of the mechanical connector element. More preferably, a radial thickness of the energy absorbing layer is at least 5 mm, more preferably at least 10 mm at the location of the mechanical connector element, in particular radially under the at least one mechanical connector element. In other words, at the location of the mechanical connector element, the helmet should not be free of material of the energy absorbing layer. Ifthere were not a minimum thickness of the energy absorbing layer at the location of said mechanical connector element, said mechanical connector element could impact the head of a user of the helmet when the helmet is impacted during an accident. By well positioning the mechanical connector element and by providing a minimum thickness of the energy absorbing layer at the location of the mechanical connector element, a relatively safe helmet in line with standard safety requirements can be provided. Of course, a thickness of the energy absorbing layer may be higher over the rest of the helmet where there is no mechanical connector element, for example in between more or less 10 and more or less 50 mm, more preferably between more or less 20 and substantially 30 mm.

[0009] The mechanical connector element can for example be a discrete element. A discrete element is to be understood as a separate, stand-alone element or component, not incorporated or not integrated into the energy absorbing layer and / or the substantially rigid outer shell. As a result, a discrete element needs a separate step in an assembly of the helmet. A discrete mechanical connector element may simplify a manufacturing process since the substantially rigid outer shell, the energy absorbing layer and the mechanical connector element may be manufactured separately, each in a substantially optimal way.

[0010] The discrete mechanical connector element may advantageously be a rim connector including a groove configured to receive a rim of the energy absorbing layer and / or a rim of the substantially rigid outer shell. Attachment of the energy absorbing layer to the substantially rigid outer shell may be obtained with a single rim connector or with a plurality of rim connectors placed along a rim of the energy absorbing layer or of the substantially rigid outer shell. The rim connector may for example be substantially U-shaped such that a rim of the energy absorbing layer and / or a rim of the substantially rigid outer shell may be squeezed between the two legs of the U- shaped element. Such a rim connector can facilitate assembling of the helmet since the rim connector only needs mounting on a free and easily accessible rim of the helmet. Moreover, a shape of the helmet need not be heavily adapted, which may be advantageous in terms of cost reduction for adapting moulds for manufacturing the energy absorbing layer.

[0011] The rim connector can preferably include at least one snap connector element configured to provide a snap connection with the substantially rigid outer shell. Such a snap connector element, such as a cantilever snap-fit, may be configured to snap behind a corresponding ridge or any other interlocking component on an inner or on an outer surface of the substantially rigid outer shell. A permanent snap connector element can be mounted relatively easily but can hardly be released without breaking either the snap connector element and / or the corresponding interlocking component.

[0012] The rim connector may advantageously be a circum-cranial rim connector. In other words, the rim connector has a substantially toroidal shape such that a groove in single rim connector can receive an entire rim of the substantially rigid outer shell and of the energy absorbing layer. In this way, the rim connector can mechanically attach the substantially outer shell to the energy absorbing layer over a maximal attachment length, thus maximally improving solidity of the attachment, while the rim connector, being a single component, can be mounted in a single operation.

[0013] Additionally, and / or alternatively, the discrete mechanical connector element may be an insertable connector element configured to extend through the substantially rigid outer shell and at least partly into the energy absorbing layer. The insertable connector element may directly engage and grip into the energy absorbing layer. The energy absorbing layer may or may not include a dedicated recess configured to receive said insertable connector. The insertable connector element may be used advantageously at one or more locations over the helmet, not only along a rim and can provide a more centrally located attachment between the substantially rigid outer shell and the energy absorbing layer.

[0014] The insertable connector element can preferably include at least two, preferably four, upstanding outwardly extending walls, the walls being configured to engage the energy absorbing layer. The walls are slightly outwardly inclined, i.e. a distance between two opposing walls at a first end or base end is smaller than a distance between the two opposing walls at a second end, the second end being a free top end configured to be inserted into the energy absorbing layer. This outward extension of the walls of the insertable connector can provide an outward force on the energy absorbing layer such that the insertable connector can be clamped into the energy absorbing layer. Said at least two upstanding outwardly extending walls, in particularan outward side of said walls, may further include one or more clamping elements configured to improve a clamping or grip of said walls into the energy absorbing layers. Said clamping elements may for example include a plurality of ridges, or any type of material roughness, or snap-fit elements, or any other kind of grip improving element. The insertable connector element, in particular at least one of said upstanding walls, may further include at least one ridge configured to engage an inner side of the substantially rigid outer shell. Said ridge may function as a snap-fit element between said insertable connector element and said substantially rigid outer shell.

[0015] The insertable connector element may further include a flange extending circumferentially outwardly, the flange being configured to engage the substantially rigid outer shell, in particular an outer side of said substantially rigid outer shell. The circumferential direction is to be understood as the direction substantially perpendicular to the radial direction. In other words, the circumferential extension is an extension along the surface of the substantially rigid outer shell, which may be considered as a portion being substantially spherical. The flange is configured to be substantially in parallel with said substantially rigid outer shell when the insertable connector element has been inserted into the helmet. Said flange may therefore be slightly curved, and a curvature of said flange may be configured to match a curvature of the helmet at the location of insertion of said insertable connector element. The substantially rigid outer shell may, but need not, include a recess configured to receive said flange.

[0016] In an advantageous way, the helmet can further comprise at least one through- hole extending through the substantially rigid outer shell and the energy absorbing layer. Said through-hole may for example be a ventilation hole or any other functional hole included in the helmet, for example to give access to an operating element for an adjustment mechanism of a head-basket of a helmet. Instead of a functional through- hole, which the helmet may include anyway, the through-hole may be a dedicated through-hole for connection purposes only. The insertable connector element can then be configured to extend at least partly in said at least one through-hole, for example in a ventilation hole. A shape of said insertable connector element may then match a shape of said through-hole. The at least two upstanding outwardly extending walls of the insertable connector element may then be configured to engage the energyabsorbing layer sideways in the through-hole. Said energy absorbing layer may include a recess inside said through-hole to receive a respective upstanding wall such that a minimal thickness of the energy absorbing layer is present radially under said at least one upstanding wall.

[0017] The insertable connector element may advantageously include a substantially central through-hole. Said through-hole can provide a relatively light-weight insertable connector element. Said through-hole may also provide space to a lighting element of the helmet, which may be mountable into the insertable connector element rather than into the helmet directly. When the insertable connector element is configured to be inserted into a ventilation hole of the helmet, the through-hole of the insertable connector element can be configured to at least partially align with the ventilation hole of the helmet to allow ventilation through the helmet. The through-hole in the insertable connector element need not be perfectly central but can just provide a substantially toroidal shape, i.e. having a hole in the middle, to the insertable connector element. A shape of an outline of said insertable connector element can match a shape of a ventilation hole of the helmet, and can be substantially rectangular, triangular, round, or polygonal.

[0018] The insertable connector element may further include a strap connection element to which safety straps are attachable. A helmet generally includes at least one safety strap configured to attach the helmet to a user’s head. Such a strap connection element may for example include a further upstanding wall including a slit through which a safety strap can extend. Such a further upstanding wall may, but need not, be substantially in parallel with one of the outwardly extending upstanding walls configured to squeeze the insertable connector element into the energy absorbing layer. Alternatively, the strap connection element may include a slit in any other part of the insertable connector element through which a safety strap can extend.

[0019] Instead of a discrete mechanical connector element, the mechanical connector element may advantageously be an integrated connector element integrated into the substantially rigid outer shell. In this way, assembly of the helmet may be simplified. The integrated connector element is preferably integrated to an inner side of the substantially rigid outer shell, which is the side of the substantially rigid outer shelldirectly engaging the energy absorbing layer. Different types of integrated connector elements may be contemplated depending on the way the energy absorbing layer is engaged: the integrated connector element may be configured to clamp, to grip, to stick into, or to extend in any other way into the energy absorbing layer.

[0020] An inner side of the substantially rigid outer shell includes at least one inwardly extending protrusion forming the integrated connector element and which is configured to engage the energy absorbing layer. Inwardly extending is defined radially inwards, so towards a head of a user when the helmet is worn by a user. Said protrusion may for example be a pin-like protrusion configured to extend into the energy absorbing layer. Said pin-like protrusion may for example include barbs to improve an engagement between said integrated connector element and the energy absorbing layer. Alternatively, said protrusion may for example be a protruding surface configured to be received in a corresponding recess in the energy absorbing layer such that said integrated connector element can provide a clamping engagement with the energy absorbing layer. Still alternatively, the integrated connector element may be a protrusion including a substantially rough surface, for example through a ribbed structure, configured to grippingly engage the energy absorbing layer.

[0021] A rim of the substantially rigid outer shell includes at least one inwardly extending flange forming the integrated connector element, wherein said flange is configured to hook under a rim of the energy absorbing layer. Said inwardly extending flange may extend along only a part of the rim of the substantially rigid outer shell to facilitate assembly, for example only along a front of the helmet or only along a back of the helmet or along a side of the helmet. Such an integrated connector element is relatively easy to assemble since it just hooks under a rim of the energy absorbing layer. The energy absorbing layer can preferably, but need not, include a corresponding recess configured to receive said inwardly extending flange. This type of integrated connector element can provide a clamping engagement between the substantially rigid outer shell and the energy absorbing layer.

[0022] The helmet can advantageously include a plurality of mechanical connector elements, of which at least a first mechanical connector element is a discrete connector element as previously described, and at least a second mechanical connector elementis an integrated connector element as described above. Alternatively, the helmet can include a plurality of integrated connector elements or a plurality of discrete connector elements. In this way, different types of engagement can be combined, such as a clamping engagement, a snap-fit engagement, a frictional engagement or any other suitable type of engagement known to the person skilled in the art. By using a plurality of mechanical connector elements, connection between the substantially rigid outer shell and the energy absorbing layer can be spread over the helmet, providing a relatively solid helmet. Combining a discrete mechanical connector element, for example an insertable connector element or a rim connector, and an integrated connector element, for example the inwardly extending flange of the substantially rigid outer shell, allows a relatively easy manufacturing and assembly I disassembly of the helmet while still providing a helmet satisfying high safety requirements.

[0023] One of the first mechanical connector element and the second mechanical connector element may preferably be configured to be located at a front side of the helmet when worn by a user, while the other of said first mechanical connector element and said second mechanical connector element may be configured to be located at a rear side of the helmet when worn. In this way, the locations of connections may be optimally spread over the helmet while maintaining a substantially symmetric helmet with respect to a median or sagittal plane.

[0024] According to a second aspect of the invention, there is provided a method for assembling a helmet having the features of claims 18 to 20. The method can provide one or more of the above-mentioned advantages.Brief Description of the Drawings

[0025] Fig. 1 shows an exploded side view of a preferred embodiment of a helmet according to a first aspect of the invention;

[0026] Figs. 2a and 2b show a perspective front view and a perspective rear view respectively of the mechanical connector element of the helmet of Figure 1 ;

[0027] Figs. 3a and 3b show a side view and a rear view respectively of the helmet of Figure 1 ;

[0028] Fig. 4 shows a schematic cross-sectional side view along section A - A of a second embodiment of a helmet according to a first aspect of the invention;

[0029] Fig. 5 shows a schematic cross-sectional side view along section A - A of a third embodiment of a helmet according to a first aspect of the invention;

[0030] Fig. 6 shows a schematic cross-sectional side view of a fourth embodiment of a helmet according to a first aspect of the invention;

[0031] Fig. 7 shows a schematic cross-sectional side view of a fifth embodiment of a helmet according to a first aspect of the invention;

[0032] Fig. 8 shows a schematic cross-sectional side view of a sixth embodiment of a helmet according to a first aspect of the invention;

[0033] Fig. 9 shows a schematic cross-sectional side view of a seventh embodiment of a helmet according to a first aspect of the invention;

[0034] Fig. 10 shows a side view of an eighth embodiment of a helmet according to a first aspect of the invention;

[0035] Fig. 11 a shows a top view of the helmet of Figure 10;

[0036] Fig. 11 b shows a schematic cross-sectional view along section A - A of the helmet of Figure 11a;

[0037] Fig. 12 shows an exploded perspective view of a nineth embodiment of a helmet according to a first aspect of the invention;

[0038] Fig. 13 shows a side view of the helmet of Figure 12; and

[0039] Fig. 14 shows a schematic cross-sectional view of part of the helmet of Figure 12.Detailed Description of Embodiment(s)

[0040] Figure 1 shows an exploded side view of a preferred embodiment of a helmet 1 according to a first aspect of the invention. The helmet 1 protects a wearer’s head, in particular during sports activities such as for example during cycling, mountain-biking, bicycle racing or other sports. The helmet 1 comprises an energy absorbing layer 2 configured to absorb energy at impact on the helmet 1 , which may occur during a fall or an accident. Said energy absorbing layer 2 may for example be manufactured in expanded polystyrene (EPS), in expanded polyurethane (EPU), in expanded polypropylene (EPP) or in any other suitable crushable foam. The energy absorbing layer 2 may be relatively thick in a normal direction to the surface depending on a field of use of the helmet. The energy absorbing layer of a helmet for motor sports may for example be thicker than the energy absorbing layer of a helmet for cycling. The helmet 1 further comprises a substantially rigid outer shell 3 configured to at least partly engage and cover an outer surface 2a of the energy absorbing layer 2. Said substantially rigid outer shell 3 may for example be manufactured in carbon fibre, polycarbonate, polyethylene terephthalate (PET), polyvinylchloride (PVC) or acrylonitrile butadiene styrene (ABS). The outer shell 3 is generally thinner than the energy absorbing layer 2 to make a relatively light-weight helmet. Instead of bonding the energy absorbing layer 2 to the substantially rigid outer shell 3 by inmoulding or by using an adhesive product, the helmet 1 according to an aspect of the present invention further comprises at least one mechanical connector element configured to mechanically attach said outer shell 3 to the energy absorbing layer 2 in a substantially permanent, fixed and adhesive-free way. The preferred embodiment shown in Figure 1 includes two mechanical connector elements 4, 5, in particular a first mechanical connector element 4 integrated into the substantially rigid outer shell 3 and a second mechanical connector element 5 which is a discrete mechanical connector. The former mechanical connector element 4 may be formed by a rim of the substantially rigid outer shell 3 including an inwardly extending flange 6. Said inwardly extending flange 6 is configured to hook under a rim of the energy absorbing layer 2. The flange 6 is preferably located at a front side of the helmet when worn. An inward extension of the flange 6 may vary along said flange 6, including a maximal inward extension around a middle of the flange 6, which may coincide with a centre line of the helmet 1 . Optionally, the energy absorbing layer 2 may further include a corresponding indentation, recessnotch or groove 7 configured to receive said flange 6. When assembling the helmet 1 , the substantially rigid shell 3, in particular the inwardly extending flange 6, can first be hooked under the rim of the energy absorbing layer 2, which can then function as a hinge. The substantially rigid outer shell 3 can then be moved downwards around said hinge to engage and at least partially cover the energy absorbing layer 2. The second mechanical connector 5, which is a separate, discrete element, may then be inserted, thus providing a glueless and fixed engagement between said substantially rigid outer shell 3 and the energy absorbing layer 2, as shown in Figures 4a and 4b.

[0041] Figures 2a and 2b show a perspective front view and a perspective rear view respectively of the mechanical connector element of the helmet of Figure 1 , in particular of the second mechanical connector element 5. The mechanical connector element 5 may have a substantially rectangular shape, but any other shape is possible as well. The mechanical connector element 5 is preferably configured to be received in a ventilation hole of the helmet 1 , but this need not be the case. If not received in a ventilation hole, the mechanical connector element may for example be configured to be received in a dedicated recess in the energy absorbing layer 2. The mechanical connector 5 can preferably include at least two, preferably four, upstanding walls 8, the walls being configured to engage the energy absorbing layer 2. The walls 8 preferably extend outwardly, meaning that a distance between two opposing walls at a distal end is larger than at a proximal end of said walls 8. Thanks to the outward extension of the walls 8, the mechanical connector element 5 can be received in the energy absorbing layer 2 in a friction fit. In other words, the mechanical connector element 5 may be configured to be clamped or squeezed into the energy absorbing layer 2. Said upstanding walls 8 extend preferably along a circumference of the mechanical connector element 5. It is further preferred that there is an opening 9 between adjacent walls 8, in particular between adjacent walls at a corner of the connector element 5, in particular in between adjacent walls 8 along different sides of a polygonal shape of the mechanical connector element 5. The opening 9 can allow a higher outward extension, thus a better friction fit and an easier insertion into the energy absorbing layer 2 than without the opening 9. A side of the outwardly extending walls 5 configured to be facing the energy absorbing layer 2 can further include at least one, preferably a plurality of ridges 10, configured to engage the energy absorbing layer 2. Said ridges can improve an adherence of the mechanical connector element 5 to the energy absorbing layer.Said ridges 10 may for example include a substantially triangular cross-section or any other appropriate shape. The ridges 10 may be oriented such that insertion of the mechanical connector element 5 into the energy absorbing layer is facilitated, whereas said orientation of the ridges may complicate extraction of the mechanical connector element 5 from the energy absorbing layer 2. The ridges 10 may also be configured to at least slightly damage the energy absorbing layer 2 when the helmet is disassembled at an end of the helmet’s lifetime, in particular when the mechanical connector 5 is removed. The mechanical connector element 5 can further include a flange 11 extending circumferentially outwardly, the flange 11 being configured to engage the substantially rigid outer shell 3. The mechanical connector element 5 can also include at least one further ridge 12, and preferably a plurality of further ridges 12, configured to engage an inner side of the substantially rigid outer shell 3. In this way, the substantially rigid outer shell 3 may be clamped between said flange 11 and the at least one further ridge 12. In an advantageous embodiment, the mechanical connector element 5 can further include a light receiving structure 13 configured to allow mounting of a light element 15 into the helmet.

[0042] Figures 3a and 3b show a side view and a rear view respectively of the helmet of Figure 1 , when the helmet is assembled for use. The helmet can generally further comprise a head basket 21 comprising an adjustment element 22 configured to adjust the head basket 21 to a head of a user of the helmet 1 . The helmet 1 can include one or more ventilation holes 20 extending through the substantially rigid outer shell 3 and the energy absorbing layer 2. The one or more ventilation holes 20 may be distributed over the helmet 1 , preferably symmetrically with respect to a centre line dividing the helmet 1 in a left side and a right side. In this embodiment, the substantially rigid outer shell 3 is fixedly and permanently connected to the energy absorbing layer 2 via the inwardly extending flange 6 at a front side of the helmet 1 and via the second mechanical connector element 5 at a rear side of the helmet 1 . The second mechanical connector element 5, as shown in Figures 2a and 2b, may be advantageously configured to be received in a ventilation hole 20 of the helmet 1 . To ensure ventilation through the helmet in spite of the mechanical connector element 5 being inserted into one of the ventilation holes 20 of the helmet 1 , the mechanical connector element 5 may include a central through-hole 14. Any of the ventilation holes 20 may be configured to receive the mechanical connector element 5. Alternatively, a plurality ofmechanical connector elements received in ventilation holes may be used to connect the substantially rigid outer shell 3 to the energy absorbing layer 2, for example one mechanical connector element per ventilation hole for at least some of the ventilation holes. In a preferred embodiment, the mechanical connector element 5 of Figures 2a and 2b may located and placed centrally on a helmet, for example along a centre line dividing the helmet into a right half and a left half. More preferably, the mechanical connector element may be located at a rear side of the helmet, most preferably substantially centrally at a rear side of the helmet 1 , as shown in Figure 3b. The mechanical connector element 5 may advantageously include a light, of which a colour may depend on a location of the light on the helmet, for example a red light indicating a rear side. Mechanical connector elements placed on a side of a helmet could for example include orange lights and / or mechanical connector elements located at a front side of the helmet could include a white light.

[0043] Figure 4 shows a schematic cross-sectional side view along section A - A of a second embodiment of a helmet according to a first aspect of the invention. The first mechanical connector element 4 may be substantially the same as shown in Figures 1 , 3a and 3b but the second mechanical connector element 50 may differ from the embodiment shown in Figures 2a, 2b and 3b in that the second mechanical connector element 50 does not include any central through-hole 14 such that the second mechanical connector element 50 closes off the ventilation hole in which it is inserted. The fixed and permanent connection between the mechanical connector element 50 and the energy absorbing layer 2 and the substantially rigid outer shell 3 is obtained in the same way as for the first embodiment. In particular, the mechanical connector element 50 can include at least two outwardly extending upstanding walls 8. A side of said upstanding walls 8 configured to engage the energy absorbing layer 2 may include a plurality of ridges 10. Said plurality of ridges 10 only improves adherence of the mechanical connector element 50 to the energy absorbing layer, but even without said ridges 10, the mechanical connector element 50 is clamped into the EPS through the outwardly extending side walls 8. The mechanical connector element 50 can further include a flange 11 extending circumferentially outwardly, the flange 11 being configured to engage the substantially rigid outer shell 3, which may, but need not, include a corresponding recess to receive said flange 1 1 . The mechanical connector element 5 can also include at least one further ridge 12, and preferably a plurality offurther ridges 12, configured to engage an inner side of the substantially rigid outer shell 3. In this way, the substantially rigid outer shell 3 may be clamped between said flange 11 and the at least one further ridge 12, as shown in the enlarged part of Figure 4.

[0044] Figure 5 shows a schematic cross-sectional side view along section A - A of a third embodiment of a helmet according to a first aspect of the invention. This third embodiment of a helmet also includes two mechanical connector elements: the first mechanical connector element 4 which is the same as in Figure 4, and a second mechanical connector element 60 which differs from the mechanical connector element 50 shown in Figure 4 in that the mechanical connector element 60 is not received in a ventilation hole. Instead, the energy absorbing layer 2 can include a recess 23 configured to receive the mechanical connector element 60. The mechanical connector element 60 may include a through-hole 14 similar to the embodiment shown in Figure 3b. While the hole is not configured to allow ventilation, the hole 14 can be configured to allow operation of an operating element 24 of a head basket 21 of the helmet. Since such an operating element 24 of a head basket is preferably located at a substantially central rear side of the helmet, the recess 23 and the mechanical connector element 60 are also placed at a rear of a helmet, in analogy with the embodiment shown in Figure 3b. Connection between the mechanical connector element 60, the energy absorbing layer 2 and the substantially rigid outer shell 3 may be provided in the same way as previously explained, for example as in Figure 4. Ventilation through the helmet can be provided by a ventilation hole 20 at a front side of the helmet and may for example be coverable by a sliding element 25 and / or by tiltable slats.

[0045] Figure 6 shows a schematic cross-sectional side view along section A - A of a fourth embodiment of a helmet according to a first aspect of the invention. This fourth embodiment of a helmet also includes two mechanical connector elements: the first mechanical connector element 4 which is the same as in Figure 4, and a second mechanical connector element 70 which differs from the mechanical connector element 50 shown in Figure 4 with respect to at least two features: the mechanical connector element 70 is configured to be received in the energy absorbing layer 2 directly rather than in a ventilation hole or a recess. In other words, the energyabsorbing layer 2 extends in and fills the space between the at least two upstanding walls 8 contrary to preceding embodiments. The energy absorbing layer 2 may however, but need not, include dedicated receiving spaces configured to receive the outwardly extending upstanding walls 8 to facilitate insertion of the mechanical connector element 70. The mechanical connector element 70 is further located at a top side of the helmet rather than at a rear side. Connection between the mechanical connector element 60, the energy absorbing layer 2 and the substantially rigid outer shell 3 may be provided in the same way as previously explained, for example as in Figure 4, as can be seen in the enlarged part of Figure 6. In particular, the outwardly extending walls 8 of the mechanical connector 70 can provide a tensioning fit of the connector 70 in the energy absorbing layer 2 and the substantially rigid outer shell can be squeezed between the further ridge 12 and the flange 11 of the mechanical connector element 70.

[0046] Figure 7 shows a schematic cross-sectional side view along section A - A of a fifth embodiment of a helmet according to a first aspect of the invention. This fifth embodiment of a helmet also includes two mechanical connector elements: the first mechanical connector element 4 which is the same as in Figure 4, and a second mechanical connector element 30 which is an integrated connector element integrated into the substantially rigid outer shell 3. An inner side 3b of the substantially rigid outer shell 3 includes a series of irregularities 31 , for example a plurality of ridges, or any other protrusions extending from said inner side and configured to engage the energy absorbing layer 2. Different shapes of protrusions may be used. More preferably, said irregularities or protrusions may be configured to at least slightly damage the energy absorbing layer 2 when the substantially rigid outer shell 3 is separated from the energy absorbing layer 2 at an end of lifetime of the helmet.

[0047] Figure 8 and Figure 9 show a schematic cross-sectional side view along section A - A of a sixth, respectively seventh, embodiment of a helmet according to a first aspect of the invention. These embodiments show variations of integrated connector elements. In both figures, the first connector element 4 at a front side of the helmet is the same as in Figure 4. A second connector element 80, 90 is also an integrated connector element at a rear side of the helmet, as in Figure 7. The second connector element 80 shown in Figure 8 is formed by the substantially rigid outer shell includinga radially inwardly extending flange 6b configured to be received under an edge of the energy absorbing layer 2. Said edge may, but need not, include a recess configured to receive said flange 6b. Said flange 6b may extend along part of said edge of the energy absorbing layer 2, for example along a rear part of said energy absorbing layer 2. In this way, the substantially rigid outer shell 3 can be permanently and fixedly attached to said energy absorbing layer 2 without the use of any chemical bonding or adhesive by tensioning said outer shell 3 around the energy absorbing layer 2 between the two flanges 6, 6b which form the first and the second integrated connector elements 4, 80. In Figure 9, the second connector element 90 is formed by the substantially rigid outer shell 3 including one or more indents extending radially inwardly and configured to be received in corresponding indents or recesses included in the energy absorbing layer 2. Said at least one indent may be located at a rear side of the helmet, and may be spaced apart, for example along and near a lower edge of the substantially rigid outer shell 3. Again, permanent, fixed and adhesive-free attachment of the substantially rigid outer shell 3 to the energy absorbing layer 2 may be obtained by tensioning said outer shell 3 over the energy absorbing layer 2 between the first connector element 4, for example at a front side of the helmet, and the at least second integrated connector element 90, for example at a rear side of the helmet. A similar tensioning can also be obtained between a left side and a right side of the helmet.

[0048] Figure 10 shows a side view of an eighth embodiment of a helmet according to a first aspect of the invention. The helmet includes a substantially rigid outer shell 2 which is fixedly, permanently and adhesive-freely attached to the energy absorbing layer (not visible) by at least four discrete and insertable mechanical connector elements 100. At least two of said mechanical connector elements 100 are located at a first lateral side of the helmet, for example at a left side of the helmet as shown, and at least two more of said mechanical connector elements 100 are located at a second lateral side of the helmet, for example at a right side of the helmet. The mechanical connector elements 100 can have a substantially trapezoidal shape or can have any other suitable shape. The helmet can include a plurality of ventilation holes, but the mechanical connector elements 100 do not extend into said ventilation holes. The helmet may further include a set of straps 26 configured to fixate the helmet on a user’s head. The straps can generally be buckled under a chin of a user. The straps arepreferably fixedly attached to the helmet, for example to the energy absorbing layer 2 and / or to the substantially rigid outer shell.

[0049] Figure 11 a shows a top view of the helmet of Figure 10 and Figure 11 b shows a schematic cross-sectional view along section A - A of the helmet of Figure 11 a. The mechanical connector elements 100 may for example be configured substantially similarly as shown and described under Figure 6. In particular, fixed, permanent and adhesive-free attachment of the substantially rigid outer shell on the energy absorbing layer is reached through the at least two upstanding and outwardly extending side walls of the mechanical connector elements 100 and through the substantially rigid outer shell being squeezed between said flange 11 and said at least one further ridge 12. The mechanical connector elements 100 may be configured to be received directly into the energy absorbing layer 2 or may be configured to be received in a dedicated recess in the energy absorbing layer 2. In an advantageous way, the mechanical connector elements 100 may be configured to receive said straps for attachment instead of attaching said straps to the energy absorbing layer 2 and / or to the substantially rigid outer shell. Thereto, the mechanical connector elements 100 may include a strap receiving element 101 , for example an additional upstanding wall including a slit through which at least one strap is attachable. An end of the strap can for example extend through the slit, be folded back and be fixedly attached to a portion of the strap to form a loop, for example through stitching or any other fixed attachment. Alternatively, an end of the strap can extend through the slit and include a widening and / or thickening preventing the end of the strap to slip back through slit. The mechanical connector element 100 can further include a strap passage. Said strap passage may be formed by an absence of an upstanding outwardly extending wall on one side or by a slit in the upstanding and outwardly extending wall on said side. The energy absorbing layer 2 may further include a cavity 102 through which the straps can extend to the mechanical connector element 100. Alternatively, a cavity may be provided between the energy absorbing layer 2 and the substantially rigid outer shell 3.

[0050] Fig. 12 shows an exploded perspective view of a nineth embodiment of a helmet according to a first aspect of the invention. The helmet comprises again a substantially rigid outer shell 3 which is to be placed on an energy absorbing layer 2. A discretemechanical connector element, in particular a rim connector 120, is configured to fixedly, permanently and gluelessly attach said outer shell 3 on the energy absorbing layer 2. In the present embodiment, the rim connector is a circum-cranial rim connector, i.e. it is a single piece configured to engage a complete lower edge of the energy absorbing layer 2, as well as of the substantially rigid outer shell 3. In other words, the rim connector 120 may be substantially oval in top or bottom view. Alternatively, a plurality of shorter rim connectors may be used, each being configured to be placed along a lower edge of the energy absorbing layer 2.

[0051] Fig. 13 shows a side view of the helmet of Figure 12. The substantially rigid outer layer 3 is first placed on the energy absorbing layer 2 without any adhesive in between. In a next step of assembling the helmet, the rim connector is mounted to a lower edge or rim of the helmet. Thereto, the rim connector 120 can include at least one, and preferably a plurality of, snap connector elements 121 configured to provide a snap connection with the substantially rigid outer shell, for example with an inner side of a lower edge or rim 3b of the substantially rigid outer shell 3, or with an outer side of said lower ridge or rim 3b of the substantially rigid outer shell 3, which inner or outer side may include a corresponding ridge or groove to receive the snap connector element 121 .

[0052] Fig. 14 shows a schematic cross-sectional view of part of the helmet of Figure 12, in particular of the rim connector 120 when attached to the energy absorbing layer 2 and the substantially rigid outer shell 3. The rim connector 120 may have a substantially U-shaped cross-section and can include a groove 122 configured to receive a rim or edge of the energy absorbing layer 2. When the snap connector elements are configured to engage an outer side of the substantially rigid outer shell 3, then the groove 122 may be configured to received a rim of the energy absorbing layer 2 and of the substantially rigid outer shell 3. Alternatively, the rim connector 120 may include two grooves of which a first groove is configured to reive the energy absorbing layer 2 and the second groove is configured to receive the substantially rigid outer shell 3.

[0053] All of the embodiments of helmets as shown in the Figures of the present application and as described above can provide a novel and inventive solution to the difficulty of recycling helmets which has proven to be complicated due to the use ofadhesive and / or chemical bonding techniques. All of the present helmets include one or more mechanical connector elements and provide a fixed (non-sliding), permanent (not releasable due to impact) and adhesive-free attachment of the substantially rigid outer shell to the energy absorbing layer. All of these helmets can provide a high level of safety to the user. In particular, a minimum thickness of the energy absorbing layer is preferably provided radially under the mechanical connector element, under meaning in the direction of a head of the user. Said minimum thickness of the energy absorbing layer can ensure head protection in case of impact at the mechanical connector element in that said minimum thickness can prevent that extremities of the mechanical connector elements may injure a user’s head.

[0054] Although the present invention has been illustrated by reference to specific embodiments, it will be apparent to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied with various changes and modifications without departing from the scope thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. In other words, it is contemplated to cover any and all modifications, variations or equivalents that fall within the scope of the basic underlying principles and whose essential attributes are claimed in this patent application. It will furthermore be understood by the reader of this patent application that the words "comprising" or "comprise" do not exclude other elements or steps, that the words "a" or "an" do not exclude a plurality, and that a single element, such as a computer system, a processor, or another integrated unit may fulfil the functions of several means recited in the claims. Any reference signs in the claims shall not be construed as limiting the respective claims concerned. The terms "first", "second", third", "a", "b", "c", and the like, when used in the description or in the claims are introduced to distinguish between similar elements or steps and are not necessarily describing a sequential or chronological order. Similarly, the terms "top", "bottom", "over", "under", and the like are introduced for descriptive purposes and not necessarily to denote relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances and embodiments of the invention are capable ofoperating according to the present invention in other sequences, or in orientations different from the one(s) described or illustrated above.

Claims

CLAIMS1 . A helmet for protecting a wearer’s head comprising- an energy absorbing layer configured to absorb energy at impact on the helmet;- a substantially rigid outer shell configured to at least partly engage and cover an outer surface of the energy absorbing layer,- a mechanical connector element configured to mechanically attach said outer shell to the energy absorbing layer, wherein the mechanical connector element is configured to allow a substantially permanent, fixed and adhesive-free engagement between said substantially rigid outer shell and said energy-absorbing layer.

2. The helmet according to claim 1 , wherein the mechanical connector element is positioned such that a thickness of the energy absorbing layer is at least 3 mm radially at the location of the mechanical connector element.

3. The helmet according to any of the preceding claims, wherein the mechanical connector element is configured to at least slightly damage the energy absorbing layer and / or the substantially rigid outer shell, and / or is configured to get damaged itself when the helmet is disassembled.

4. The helmet according to any of the preceding claims, wherein the mechanical connector element is a discrete element.

5. The helmet according to claim 4, wherein the discrete mechanical connector element is a rim connector including a groove configured to receive a rim of the energy absorbing layer.

6. The helmet according to claim 5, wherein the rim connector includes at least one snap connector element configured to provide a snap connection with the substantially rigid outer shell.

7. The helmet according to claim 5 or 6, wherein the rim connector is a circum- cranial rim connector.

8. The helmet according to claim 4, wherein the discrete mechanical connector element is an insertable connector element configured to extend through the substantially rigid outer shell and at least partly into the energy absorbing layer.

9. The helmet according to claim 8, wherein the insertable connector element includes at least two, preferably four, upstanding outwardly extending walls, the walls being configured to engage the energy absorbing layer.

10. The helmet according to any of the preceding claims 8 to 9, wherein the insertable connector element includes a flange extending circumferentially outwardly, the flange being configured to engage the substantially rigid outer shell.

11. The helmet according to any of the preceding claims 8 to 10, the helmet further comprising at least one through-hole extending through the substantially rigid outer shell and the energy absorbing layer wherein the insertable connector element is configured to extend at least partly in said at least one hole.

12. The helmet according to any of the preceding claims 8 to 11 , wherein the insertable connector element includes a substantially central through-hole.

13. The helmet according to any of the preceding claims 8 to 12, wherein the insertable connector element includes a strap connection element to which safety straps are attachable.

14. The helmet according to any of the preceding claims 1 to 3, wherein the mechanical connector element is an integrated connector element integrated into the substantially rigid outer shell.

15. The helmet according to claim 14, wherein an inner side of the substantially rigid outer shell includes at least one inwardly extending protrusion formingthe integrated connector element and which is configured to engage the energy absorbing layer.

16. The helmet according to any of the preceding claims 14 or 15, wherein a rim of the substantially rigid outer shell includes at least one inwardly extending flange forming the integrated connector element, wherein said flange is configured to hook under a rim of the energy absorbing layer.

17. The helmet according to any of the preceding claims, wherein the helmet includes a plurality of mechanical connector elements, of which at least a first mechanical connector element is a discrete connector element according to any of the preceding claims 4 to 13 and at least a second mechanical connector element is an integrated connector element according to any of the preceding claims 14 to 16.

18. The helmet according to claim 17, wherein one of the first mechanical connector element and the mechanical second connector element is configured to be located at a front side of the helmet when worn by a user, and wherein the other of said first mechanical connector element and said second mechanical connector element is configured to be located at a rear side of the helmet when worn.

19. Method for assembling a helmet, in particular a helmet according to any of the preceding claims, comprising the steps of- providing an energy absorbing layer configured to absorb energy at impact on the helmet;- providing a substantially rigid outer shell configured to at least partly engage and cover an outer surface of the impact absorbing layer;- providing at least one mechanical connector element configured to mechanically attach said outer shell to the energy absorbing layer;- positioning said outer shell on the energy absorbing layer;- having the at least one mechanical connector element permanently, fixedly and adhesive-freely attach said outer shell to the energy absorbing layer.

20. Method according to claim 19, wherein the step of positioning said outer shell on the energy absorbing layer includes hooking at least one inwardly extending flange of a rim of the substantially rigid outer shell under the energy absorbing layer and hingedly bringing down said outer shell on the energy absorbing layer, and wherein the step of having the at least one mechanical connector permanently, fixedly and adhesive-freely attach said outer shell to the energy absorbing layer includes inserting the at least one mechanical connector into a ventilation hole of the helmet.

21. Method according to claim 19, wherein the step of having the at least one mechanical connector element permanently, fixedly and adhesive-freely attach said outer shell to the energy absorbing layer includes inserting a rim of said energy absorbing layer and a rim of said substantially rigid outer shell into a groove included in the at least one mechanical connector element.

Images