Inflatable protective device

Abstract

An inflatable device, such as a helmet, comprises an arrangement of a plurality of inflatable chambers (18) that are defined by respective chamber walls. At least the external chamber walls, i.e., the chamber walls that contribute to and preferably constitute an external surface of the chamber arrangement comprise a composite material, which comprises a textile material and a fluid tight, elastic material that are permanently connected to each other. Preferably the composite material may be made of the textile material and the fluid-tight, elastic material, optionally with respective coatings or treatments to better cope with environmental influences. Arrangement of the composite material is such that the fluid-tight, elastic material provides the inner surface of the respective external chamber walls, consequently the composite material is configured to have the fluid-tight, elastic material at at least one surface.

Description

[0001] Inflatable protective device

[0002] Field

[0003] The present invention generally relates to protective devices and particularly to inflatable protective devices. In some aspects the present invention relates to inflatable helmets.

[0004] Introduction

[0005] Protective devices are widely used, e.g., as personal protective equipment (PPE), during sports or when using certain means of transport. Furthermore, protective devices may for example be used to protect objects, particularly goods, e.g., during shipment. Some examples of protective devices may be different kinds of helmets or protectors. In the following, the present invention is mainly described with respect to helmets. However, it will be understood that this generally only serves as an example for a protective device. Unless stated otherwise.

[0006] Helmets are known as safety equipment for example used during sports activities such as cycling. Such helmets are typically made of a hard shell into which a hard foam such as expanded polystyrene (EPS) is directly expanded. The shell is typically made of plastic, e.g., polycarbonate or acrylonitrile butadiene styrene (ABS). The EPS has some shockabsorbing properties that may protect the head in case of an impact.

[0007] However, the hard foam ages with time and may become porous, consequently losing its protective function. These processes can be amplified through external influences, such as weather conditions, sweat, small impacts and shocks during normal use (e.g., hitting the wall when carrying the helmet in hand), etc. The actual state of the hard foam can oftentimes not be determined from the outside, which disadvantageously necessitates regular replacement of the helmet even though it might still appear to be fully intact. Similarly, in case of an impact, such helmets must be replaced as the hard foam is typically damaged even though not always visible from the outside. In other words, while the helmet may protect the head of the wearer it disadvantageously needs replacement after each impact caused by a fall or accident, i.e., an impact that goes beyond a small impact during normal use. Generally, when reference is made to an "impact", such impacts, which may also be referred to as significant impact, are meant.

[0008] Furthermore, these known helmets are often bulky and inconvenient, which may particularly disadvantageous when not wearing the helmet as they must be carried around or safely stored.

[0009] Similarly, other protective devices such as protectors may break or otherwise be permanently damaged in case of a significant impact. Furthermore, they may similarly be bulky and inconvenient to store as for example protectors may comprise hard and stiff polymer elements. WO 2020 / 093125 Al discloses an inflatable helmet that is supplied in deflated form and can be inflated at any time for immediate use. The helmet comprises an inflatable chamber made of a pair of flexible, polymeric films. However, the outer surface of the helmet is provided through a polymer film that also defines the inflatable chamber and may thus disadvantageously be easily damaged. Furthermore, the disclosed chamber completely spans over the protected area of the wearer's head and does not comprise any separation into sub chambers and / or structural support, which may be disadvantageous in terms of stability of the chamber and may allow air to redistribute too quickly in case of an impact, which may result in insufficient protection of the wearer.

[0010] US 2022 / 0248794 Al discloses a device for protecting an object or a person, comprising a sealed elastic membrane intended for receiving a gas and a fibrous envelope containing said membrane, wherein in the rest state, the membrane has a size different to that of the envelope and the envelope containing the membrane can be folded. Thus, membrane and envelope are completely disconnected from each other. This may have some disadvantages: The envelope may comprise recesses to aid with evacuation of air that may allow introduction of impurities into the inside of the envelope, which may potentially damage the membrane, the membrane cannot be inspected for any visual damage, and as it is completely separated from the envelope it may become twisted and / or folded in a way that does not allow proper inflation of the membrane anymore and may thus render the device unsafe and useless. Furthermore, manufacture of such a device is difficult since care needs to be taken not to damage the membrane when sewing the envelope which typically requires significant amount of manual labour and can hardly be automated.

[0011] EP 4 018 865 Al discloses an inflatable helmet comprising a plurality of elongate members, each elongate member comprising at least one chamber wall defining an inflatable chamber; wherein at least two adjacent elongate members are in fluid communication with each other; and wherein the plurality of elongate members is inflatable so as to adjust the inflatable helmet from a collapsed state to an inflated state in which at least one pair of adjacent elongate members abut one other along at least a portion of their respective chamber walls.

[0012] EP 1 773 148 Al discloses a protective helmet comprising an inner hood (1) consisting of a spacer knitted fabric consisting of a monofilament yarn. Said hood is covered by a pneumatic central layer (4) which can be pressurized by means of compressed air and can be inflated by means of an air pump (5) which can be, for example, removed and provided with valves (6). An outer layer (10) consists of an inner textile layer (11) which lies over the pneumatic central layer (4), and plates (12) which are fixed to the textile layer (11), for example by adhesion. Said plates (12) consist, for example, of plastic, composite materials, or natural materials. The plates (12) can be arranged in such a way that joints (13) are created therein between, the outer layer (10) thus being provided with a certain elasticity in order to cater for different head shapes and sizes. Summary

[0013] In light of the above, it is an object to overcome or at least alleviate the shortcomings and disadvantages of the prior art. That is, it is an object of the present invention to provide an improved inflatable protective device, such as a helmet and a respective manufacturing method.

[0014] These objects are met by the present invention.

[0015] In a first embodiment, the inflatable device comprises an arrangement of a plurality of inflatable chambers that are defined by respective chamber walls. At least the external chamber walls, i.e., the chamber walls that contribute to and preferably constitute an external surface of the chamber arrangement comprise a composite material, which comprises a textile material and a fluid tight, elastic material that are permanently connected to each other. Preferably the composite material may be made of the textile material and the fluid-tight, elastic material, optionally with respective coatings or treatments to better cope with environmental influences. Arrangement of the composite material is such that the fluid-tight, elastic material provides the inner surface of the respective external chamber walls, consequently the composite material is configured to have the fluid-tight, elastic material at at least one surface.

[0016] Generally, the chamber arrangement may allow for the protective device to be inflated and deflated such that the protective device can advantageously be stored in a compacted form, which may render transportation and storage of the protective device easier when not in use. Furthermore, this may advantageously allow to provide a light and / or material efficient protective device with high usability.

[0017] The composite material may comprise a layer of the textile material and at least one layer of the fluid-tight, elastic material. In other words, the composite material may comprise layers of respective materials that are permanently interconnected, e.g., laminated and / or adhered.

[0018] The fluid-tight, elastic material may be an elastomer. In particular, the fluid-tight, elastic material may be a thermoplastic elastomer (TPE), preferably a thermoplastic polyurethane (TPU) or a thermoplastic copolyester (TPC). Additionally or alternatively, the fluid-tight, elastic material may be a synthetic film. In particular, the fluid-tight, elastic material may be a thermoplastic elastomer (TPE) film, preferably a thermoplastic polyurethane (TPU) or a thermoplastic copolyester (TPC) film.

[0019] The textile material may be one of a knitted fabric, a crocheted fabric, or a woven fabric, wherein the knitted fabric may be a weft knitted fabric or a warp knitted fabric. Generally, the textile material may be made of high density Polyethylen (HDPE), ultra-high-molecular- weight polyethylene (UHMMWPE), polyester, or polyamide, e.g., nylon or Kevlar. Preferably, the textile material may be made of polyester or nylon. The composite material may only comprise the textile material and the fluid-tight, elastic material. That is, the composite material may not comprise any further materials. However, it will be understood that the composite material may nonetheless comprise glue and / or specific coatings / substances for better resilience with respect to environmental influences.

[0020] The textile material and the fluid-tight, elastic material may be materially bonded to each other to provide the permanent connection. In some embodiments, the textile material and the fluid-tight, elastic material may be permanently connected to each other through the application of heat and pressure. The textile material and the fluid-tight, elastic material may be permanently connected to each other through lamination, preferably through hot lamination. Additionally or alternatively, the textile material and the fluid-tight, elastic material may be permanently connected to each other through adhesion.

[0021] The composite material may further be arranged such that the textile material provides an outer surface of the respective external chamber walls. That is, the textile material comprised by the composite material may be arranged such that it provides the outer surface of the respective external chamber walls. Thus, the composite material may be configured to have the textile material at at least one of its surfaces. The composite material may further be arranged such that the textile material provides an outer surface of the chamber arrangement.

[0022] The composite material of the external walls may comprise a thickness of 0.1 mm to 2.5 mm, preferably, 0.3 mm to 2 mm, more preferably 0.5 mm to 1.5 mm.

[0023] The composite material may be foldable. Furthermore, the chamber arrangement may be foldable in a deflated state. Preferably, the protective device may be foldable in a deflated state. Most preferably, the protective device may be foldable in a deflated state in all directions. As outlined above, this may advantageously allow for the protective device to be stored in a compacted form, which may render transportation and storage of the protective device easier when not in use.

[0024] The protective device may further comprise a valve, configured to provide access to the inflatable chambers in order to inflate / deflate said chambers. In other words, the valve may allow to access the chamber arrangement from the outside and to inflate and deflate chambers of the chamber arrangement. Next to the valve, or integrated in the valve, is a pressure indicator to check the pressure of the inflated helmet.

[0025] The inflatable chambers may be configured to withstand an internal pressure of at least up to 2 bar, preferably at least up to 3.5 bar, more preferably at least up to 5 bar. It will be understood that whenever pressures values are given within the present application, these pressure values relate to relative pressure, i.e., they are specified relative to ambient pressure. Additionally or alternatively, the chamber arrangement may comprise a weight of at most 800 g, preferably at most 400 g, preferably at most 200 g. Similarly, the protective device may comprise a weight of at most 950 g, preferably at most 500 g, preferably at most 270 g. The relatively low weight compared to common protective devices, particularly helmets based on hard foam, may advantageously allow for easier transportation of the protective device, particularly in combination with the possibility to store it in a compacted form. Furthermore, for example a light helmet may put less strain on a wearer's neck.

[0026] Each of the plurality of inflatable chambers may be fluidly connected to at least one adjacent chamber through a respective hole and / or channel. In some embodiments, the plurality of inflatable chambers may be fluidly interconnected. That is, the plurality of inflatable chambers may each be fluidly connected with each other. In other words, the fluid connections may be such that there is a fluidic connection between all of the plurality of chambers. It will be understood that said fluidic connection may comprise other chambers and that this may principally allow air to move from an arbitrary chamber to any other chamber.

[0027] The chamber arrangement may comprise a single chamber layer. It will be understood that when comprising a single chamber layer, the chamber arrangement may preferably not comprise any chambers overlapping in a direction from the inside to the outside, i.e., a proximal-to-distal direction, of the chamber arrangement. Preferably, when comprising only a single chamber layer, all chamber walls may be external chamber walls. Alternatively, the chamber arrangement may comprise a plurality of chamber layers. In some embodiments, the chamber arrangement may comprise at most two chamber layers.

[0028] When comprising more than one chamber layer, the chamber layers may be arranged to be stacked on top of each other in a proximal-to-distal direction. Preferably, the chamber layers may be arranged such that chambers of adjacent chamber layers at least partially overlap in a proximal-to-distal direction. Thus, the chamber arrangement may comprise at least one chamber in one chamber layer that at least partially overlaps with a chamber of another, preferably adjacent chamber layer in the proximal-to-distal direction.

[0029] In one embodiment, the inflatable helmet which, when inflated, rests on the head only with its flat material side against the head.

[0030] The inflatable helmet can be folded several times in all directions when deflated.

[0031] The inflatable helmet whose shape is created from at least 1 to max. 3 large-area air chambers, which are connected by a hole and / or channel. If 3 air chambers are present they can be superimposed and connected so that weak points of at least one (preferably the outer chamber) or both chambers are covered in a complementary manner, so that the weak points of one chamber is covered by a part of one of the other chambers. These chambers can be seen as layers. In an embodiment, more than one layer may be addressed as chamber. The inflatable protective device, preferably a helmet whose in two direction curved shape is created through overlapping the arms of the form and fixing them together on each side to create kind of a half ball in the non-inflated state. The air cushions will hold in 3D shape when inflated because the fixed points on the sides hold them. To create the arms the decisive factor are the incisions on the sides with a circular weld at the end. The outer chamber has the main shaping effect while the possible at least one air chambers inside only append to the main chamber.

[0032] When the assembly of chambers is laid flat the longest 2 arms and the 2-4 other arms on the opposite, which all sit on the end of the pattern are decisive for the inflatable helmet shape. These are connected and form the basis for the elliptical basic shape to which all other arms of the development are connected.

[0033] Welded walls within an air chamber prevent ball-like inflation of the chamber and hold the 2 outer walls of an air chamber together without completely separating them (as would be the case with a complete through-welding). This provides for the chamber to have a constant or defined varying chamber thickness and can create areas that bend more easily and are conducive to the overall shape by varying the height of these walls.

[0034] Joining of all the arms on the left and right sides allows additional forcing of the air cushions into the desired shape, regardless of the method of joining.

[0035] A circular or an elongated hole can be left in the outer material at the welding points of the inner-walls so that the TPU side of the bar looks out and another attachment option for air chambers or other weldable parts such as Velcro, which allows the attachment of padding to the inside of the device or the attachment of a textile cover that serves as a cover for the helmet. This technical feature may further provide a more appealing appearance.

[0036] One or more holes can be in the circular welds from which serves as a ventilation hole.

[0037] In embodiments comprising a plurality of layers, the chamber arrangement may comprise at least one internal chamber section, and wherein internal walls of adjacent chambers of neighbouring chamber layers may be provided through a respective internal chamber section. It will be understood that the term "internal walls" can refer to chamber walls that are located within the chamber arrangement. In some embodiments, the at least one internal chamber section may not provide any external chamber wall. Alternatively, the at least one internal chamber section further provides a portion of the external chamber wall(s). That is, the internal chamber section may, in addition to providing the internal chamber walls, also provide at least a portion of one or more external chamber walls. In such a case, the internal chamber section may also comprise a composite material.

[0038] The chamber arrangement may comprise a single internal chamber section, particularly when comprising two chamber layers. The at least one internal chamber section may comprise the fluid-tight, elastic material. That is, the internal chamber section may comprise the same fluid-tight, elastic material as the composite material. Similarly, the at least one internal chamber section may comprise the textile material. That is, the internal chamber section may comprise the same textile material as the composite material. The at least one internal chamber section may comprise an internal composite material comprising the fluid-tight, elastic material and the textile material, which are permanently connected to each other. Thus, the internal composite material may comprise the same materials as the composite material comprised by the external chamber walls. The internal composite material may comprise the textile material sandwiched between the fluid-tight, elastic material, wherein the materials are permanently connected to each other. In other words, the internal composite material may be a three-layered composite material, wherein a layer of the textile material is located between a layer of fluid-tight, elastic material.

[0039] Further, the inner composite material may comprise elastic and textile material. The same may apply to the inner walls.

[0040] The chamber arrangement may comprise at least one external chamber section formed of the composite material constituting the external chamber walls. It will be understood that an external chamber section is a chamber section that may constitute only external chamber walls and particularly at least part of an external surface of the chamber arrangement. The chamber arrangement may comprise at most two external chamber sections. Alternatively, the chamber arrangement may comprise a single external chamber section.

[0041] A collection of at least one chamber section comprising at least one external chamber section and optionally at least one internal chamber section may be welded together to provide the chamber arrangement. That is, the collection of at least one chamber section may comprise at least one external chamber section and optionally, in case of more than one chamber layer, at least one internal chamber section. The internal chamber section could also have the form of a wall, which provides a constant or defined varying chamber thickness. Said collection of at least one chamber section may be welded together to provide the chamber arrangement. For example, in case of the chamber arrangement comprising only a single chamber layer the collection of at least one chamber section may preferably comprise one or two external chamber layers that are welded together to provide the chamber arrangement. In case of a single external chamber layer said external chamber layer may be folded and welded to itself to provide the chamber arrangement. The collection of at least one chamber section may comprise a plurality of external chamber sections. The plurality of external chamber sections may comprise different shapes. Additionally, the collection of at least one chamber section may comprise one internal chamber section. Welding joints of the external chamber section(s) may be located between respective neighbouring chambers of a chamber layer and at an outer rim of the respective chamber arrangement.

[0042] The plurality of inflatable chambers may comprise a tube-like shape with an elliptical or round cross section. In some embodiments, the plurality of inflatable chambers may comprise a split cross section, wherein a distal portion of the plurality of chambers comprises a different cross-section to a proximal portion of the plurality of chambers. The distal portion or the proximal portion may comprise a cross-section resembling a circular segment or an elliptical segment. The respective other portion may comprise a cross section resembling a polygonal, preferably hexagonal, segment. Such an embodiment may for example be realised by welding together tow external chamber sections that comprise different shapes, wherein one provides cross-sections resembling a segment of a polygon, preferably a hexagon and the other one provides cross-sections resembling segments of a circle or an ellipse. Such that the resulting cross-section may be split.

[0043] At least one of the plurality of inflatable chambers may be a self-contained chamber that does not comprise a closed end in its longest extension. For example, at least one of the plurality of inflatable chambers may be a chamber comprising a toroidal or torus-like shape. Additionally or alternatively at least one of the plurality of inflatable chambers may be a three-part chamber comprising three sections of tube-like chambers that are joined at their respective ends by means of a Y-piece, wherein each section approximately resembles a semi-circle or a half ellipse. In some embodiments, at least one of the plurality of inflatable chambers may be a chamber resembling the shape of a section of a ring or a section an elliptical torus. Similarly, at least one of the plurality of inflatable chambers may be a tubelike chamber with closed ends that is bend in shape of a section of a circle or a section of an ellipse.

[0044] The protective device may further comprise fixation means. The fixation means may comprise at least one webbing strap and / or a fastener, preferably a quick-release fastener. Further, the fixation means may comprise an adjustment means, configured to adjust the fixations means in length and / or size.

[0045] The protective device may be a wearable protective device. That is, a protective device configured to be worn by a person. In such a case, the protective device may thus for example be configured to protect a body part. The protective device may be a helmet. The fixation means may be configured for fixing the helmet to a wearer's head when in use. The helmet may be a sports helmet. That is, the helmet may be configured for at least one or a plurality of skating, skiing, snowboarding, hiking, cycling, riding, (kite) surfing, mountaineering, climbing, paragliding, skydiving, rafting, canyoning, bungee jumping, bodyboarding, water skiing, wakeboarding, packrafting and / or kayaking. Additionally or alternatively, the helmet may generally be configured to be used on a means of transport, such as a scooter, bicycle, or motorbike. The helmet may be a motorbike helmet configured for riding a motorbike or scooter. Preferably, the helmet may be a bicycle helmet.

[0046] Alternatively, the protective device may be a protector, e.g., a knee protector, an elbow protector, a hip protector, a wrist protector, or a spine protector. These may also be referred to as knee pad, elbow pad, hip pad and / or wrist guard. The protector may be a protector for sports, e.g., skating, volleyball, etc. The protective device may be configured as personal protective equipment (PPE). The protective device may be configured for occupational health and safety. Thus, the protective device may for example be specifically designed to be used in a working environment, PPE may for example include respective helmets and protectors. In other words, the protective device may be safety equipment for Occupational safety and health.

[0047] Alternatively, the protective device may be configured for protection of objects, such as goods. That is, the protective device may for example be configured for protecting objects during transport, e.g., shipment. This may be advantageous as it may be reusable and / or lighter compared to known packaging material.

[0048] The protective device may further comprise a pressure indicator, configured to indicate a pressure within the chamber arrangement.

[0049] In some embodiments, an adaptation layer may be provided as the most proximal chamber layer of the chamber arrangement and wherein said adaptation layer is not fluidly connected to any other chamber layer. The adaption layer may be configured to hold a pressure of less than 0.5 bar, preferably less than 0.3 bar. That is, while it may be able to withstand higher pressures it is designed to only be pressurized up to 0.5, preferably 0.3 bar in order to provide means for adjusting to various shapes. In other words, the adaptation layer may be pressurized to less than 0.5 bar, preferably less than 0.3 bar when in use. The adaptation layer may be configured to be inflated without a pump, e.g., by mouth. Such an adaptation layer may advantageously allow a comfortable fit to the shape of body part or object to be protected, and thus provide a snug fit and potentially increase wearing comfort for a user and / or increase protection of a respective object. Thus, the adaptation layer may advantageously allow for size adjustment for the protective device, e.g., in case of a wearable protective device such as a helmet. Preferably all other chamber layers of the chamber arrangement may be fluidly connected to each other.

[0050] The chamber arrangement may comprise two chamber layers that share an internal chamber section and wherein the chamber section may provide the internal chamber walls and additionally, a portion of the external chamber walls due to a difference in shape of the two chamber layers. Further, the chambers within each chamber layer may be defined through respective weld joints in the form of weld points or weld lines. The chamber layers may be fluidly connected via a single hole. The distal chamber layer may comprise a plurality of parallel fingers that are mirror-symmetrically arranged to an axis perpendicular to the fingers, wherein the fingers on either side of the axis may each respectively be joined in at least a single point, thereby creating a curvature of the chamber assembly. The joining points of the fingers can also be used to attach fixation means. The internal chamber section may comprise an internal composite material, which may comprise the textile material sandwiched between the fluid-tight, elastic material.

[0051] In another embodiment, the present invention relates to a method for manufacturing an inflatable protective device comprising a chamber arrangement of interconnected inflatable chambers, the method comprising providing at least two different materials, forming the materials, joining the materials to provide a composite material, cutting and / or punching the formed and joined materials to provide at least one external chamber section of formed composite material, and welding together a collection of at least one chamber section, comprising at least one external chamber section of formed composite material to provide the chamber arrangement. In other words, the chamber arrangement may be provided through welding together a collection of at least one chamber section, wherein said collection of at least one chamber section comprises at least one external chamber section. That is, the collection of at least one chamber section always comprises at least one external chamber section and may optionally comprise further chamber sections, particularly at least one internal chamber section. The external chamber sections may be provided through providing, forming, joining, and cutting and / or punching the material and may be formed of a composite material provided through joining the materials.

[0052] The step of forming the materials may precede the step of joining the materials to provide a composite material. Alternatively, the step of joining the materials to provide a composite material may precede the step forming the materials. Further alternatively, the step of forming the materials and the step of joining the materials to provide a composite material may at least partially be performed simultaneously.

[0053] Forming the materials may comprise forming the materials using a respective mold or forming die. The at least two materials may be layered and subsequently pressed or drawn into or onto the mold or forming die. Alternatively, at least at one of the materials may be pre-shaped to roughly approximate a desired overall shape. For example, a textile material may be inserted into the mold or forming die as a hemispherically shaped material, e.g., through 3D knitting. This may advantageously facilitate forming the materials as the preshaped material may be subjected to less strain and / or stress. For example, it may render deep drawing easier as the material would have to be stretched less. Joining the materials may comprise heating the mold or forming die. In some embodiments, the mold or forming die may be heated prior to forming of the materials, while in other embodiments the mold or forming die may be heated after forming of the materials. For example, some materials may require heating thereof to be able to deform sufficiently, while other materials may be suitable to be formed cold and heating may only be applied subsequently, e.g., to join the materials and ensure that they stay in the desired shape. That is, in the latter case the mold or forming die may only be heated once the material is already lying against a respective surface of the mold / forming die resembling the desired shape. The mold or forming die may be made from metal, preferably aluminium or steel.

[0054] Joining the materials may comprise application of heat and pressure. Generally, joining the materials may comprise materially bonding the materials to each other to provide a permanent connection. Joining the materials may comprise laminating the materials, preferably hot laminating the materials. Additionally or alternatively, joining the materials may comprise adhesion of the materials. Thus, the materials may be joined through lamination, e.g., hot lamination, and / or adhesion. In particular, laminating may comprise applying an adhesive.

[0055] Forming the materials may comprise forming by thermoforming or by forming based on active media. The active media may comprise pressurized fluid, preferably pressurized air, gas and / or steam. The method may comprise providing heated active media for joining the materials. In such a case, the active media may preferably comprise heated steam. Generally providing heated active media may advantageously allow to more efficiently heat the materials compared to only heating the mold or forming die. Furthermore, it may be sufficient to only provide heated active media, such that heating of the mold or forming die may not be required. Additionally or alternatively, the method may comprise providing heated active media for forming the materials. Heating the materials during forming may aid with forming as it may increase flexibility and / or stretchability of the material.

[0056] The at least two different materials may be provided as layers of respective materials, e.g., sheets of respective materials. Thus, the respective composite material may be a layered composite material.

[0057] The materials may comprise a fluid-tight, elastic material. The fluid-tight, elastic material may be a thermoplastic elastomer (TPE), preferably a thermoplastic polyurethane (TPU) or a thermoplastic copolyester (TPC). Additionally or alternatively, the fluid-tight, elastic material may be a synthetic film. Particularly, the fluid-tight, elastic material may be a thermoplastic elastomer (TPE) film, preferably a thermoplastic polyurethane (TPU) or a thermoplastic copolyester (TPC) film. Generally, the fluid-tight, elastic material may be provided as a layer comprising a thickness of 0.05 mm to 0.8 mm, preferably, 0.08 mm to 0.5mm, more preferably 0.1 mm to 0.2 mm.

[0058] The materials may comprise a textile material. The textile material may be one of a knitted fabric, a crocheted fabric, or a woven fabric, wherein the knitted fabric may be a weft knitted fabric or a warp knitted fabric. Generally, the textile material may be made of high density Polyethylen (HDPE), ultra-high-molecular-weight polyethylene (UHMMWPE), polyester, or polyamide, e.g., nylon or Kevlar. The textile material may be provided as a layer comprising a thickness of 0.1 mm to 3 mm, preferably, 0.5 mm to 2.5 mm, more preferably 1 mm to 2 mm. It will be understood that this relates to the thickness of the textile material prior to forming and joining thereof.

[0059] The textile material and / or the composite material may be treated with water repellent. This may advantageously allow to avoid the textile material absorbing water during rain, which may otherwise affect properties of the textile material and / or add weight to the protective device. Additionally or alternatively, the textile material and / or the composite material may be treated with an UV inhibitor or UV protectant. This may advantageously allow to protect the composite material from UV radiation of the sun, which may otherwise potentially deteriorate the composite material and / or its constituents. The composite material of the at least one external chamber section may comprise a thickness of 0.1 mm to 3 mm, preferably, 0.5 mm to 2 mm, more preferably 0.7 mm to 1.6 mm.

[0060] The composite material may be foldable and preferably the chamber arrangement may be foldable in a deflated state. Similarly, the protective device may be foldable in a deflated state.

[0061] Cutting and / or punching the formed and joined materials may comprise utilising a die. When used for the method, the forming die and the die may be provided as a single die.

[0062] The steps of providing at least two different materials, forming the materials, joining the materials to provide a composite material, and cutting and / or punching the formed and joined materials to provide at least one external chamber section of formed composite material may be repeated. This may allow to provide a plurality of external chamber sections. It will be understood that the respective mold or forming die used for forming and / or joining the materials may be different for different external chamber sections.

[0063] Welding may comprise high-frequency welding. That is, welding together a collection of at least one chamber section may comprise high-frequency welding, which may also be referred to as Radio-frequency welding and / or dielectric welding.

[0064] The method may further comprise welding a valve into the chamber arrangement configured to enable inflating and deflating of the interconnected chambers. Particularly, the method may further comprise welding a valve into one of the at least one external chamber section configured to enable inflating and deflating of interconnected chambers. Preferably, the valve may be welded into the one of the at least one external chamber section prior to welding together the collection of at least one chamber section.

[0065] The method may further comprise designing the protective device. Further, designing the protective device may comprise providing a digital model of the protective device, preferably by using a computer-aided design (CAD) software. Additionally or alternatively designing the protective device may comprise simulating a geometry of the protective device. Generally, designing the protective device may comprise utilizing artificial intelligence. Preferably, designing the protective device may comprise simulating an appearance of the protective device in an inflated state. The method may further comprise providing the at least one mold or forming die based on the designed protective device and particularly based on the digital model of the protective device.

[0066] The chamber arrangement may comprise a single chamber layer and wherein chambers comprised by the chamber arrangement may not overlap in a proximal to distal direction. Alternatively, the chamber arrangement may comprise a plurality of chamber layers. The plurality of chamber layers may be arranged such that each chamber layer comprises at least one chamber that at least partially overlaps with a chamber of an adjacent layer in the proximal-to-distal direction. In some embodiments, the plurality of chamber layers may be stacked on top of each other in a proximal-to-distal direction. Preferably, the plurality of chamber layers may be arranged such that chambers of adjacent chamber layers at least partially overlap in a proximal-to-distal direction. Adjacent chamber layers may be arranged such that weld joints within a chamber layer may overlap with at least one chamber of an adjacent chamber layer in the proximal-to-distal direction. Similarly, adjacent chamber layers may be arranged such that weld joints located within a chamber layer do not overlap with weld joints within an adjacent chamber layer in the proximal-to- distal direction. Again, it will be understood that the phrase "weld joints located within a chamber layer" serves to exclude weld joints at an outer rim of a chamber layer. This may advantageously avoid any potential weak spots when an impact would directly act on a welding joint.

[0067] At least one chamber of a chamber layer may be fluidly connected to a chamber of an adjacent chamber layer. Chambers within one chamber layer may be fluidly connected to each other.

[0068] The method may further comprise providing at least one internal chamber section. The collection of at least one chamber section may comprise at least one internal chamber section. Preferably, the collection of at least one chamber section may comprise a single internal chamber section. The internal chamber section could also have the form of a wall, which provides a constant or defined varying chamber thickness. Providing the at least one chamber section may comprise providing internal section material. The internal section material may comprise a fluid-tight, elastic material. Preferably, the fluid-tight, elastic material may be the same as comprised by the composite material of the external chamber section. Similarly, the internal section material may comprise a textile material. Preferably, the textile material may be the same as comprised by the composite material of the external chamber section. In some embodiments, providing the at least one chamber section may comprise joining the fluid-tight, elastic material and the textile material such that a layer of textile material is sandwiched between layers of fluid-tight, elastic material. Providing the at least one chamber section may further comprise cutting and / or punching the internal section material.

[0069] The collection of at least one chamber section may comprise at most two external chamber sections of formed composite material to provide the chamber arrangement. The collection of at least one chamber section may comprise a plurality of external chamber sections and wherein the external chamber sections comprise different shapes.

[0070] Welding joints of the collection of at least one chamber section may be located between adjacent chambers within a chamber layer and at an outer rim of the chamber arrangement. In some embodiments, welding joints of a chamber layer may be located within a convex surface running through the chamber arrangement.

[0071] The method may further comprise attaching fixation means to the chamber arrangement. The inflatable chambers may be configured to withstand an internal pressure of at least up to 2 bar, preferably at least up to 3.5 bar, more preferably at least up to 5 bar.

[0072] Each of the plurality of inflatable chambers may be fluidly connected to at least one adjacent chamber through a respective hole and / or channel. This may be achieved by adding respective holes and / or channels when providing and / or forming the materials. The plurality of inflatable chambers may be fluidly interconnected. That is, the plurality of interconnected inflatable chambers may each be fluidly connected with each other. Preferably, for chamber arrangements comprising a single chamber layer, these chambers may be fluidly connected by channels. Preferably, for a chamber arrangement comprising a plurality of chamber layers, the chambers may be connected through holes. Particularly, each chamber may be fluidly connected to an adjacent chamber of an adjacent chamber layer. Again, all chambers of the chamber arrangement may be fluidly connected. That is, in a chamber arrangement comprising two chamber layers, all chambers may be fluidly connected to each other solely through respective holes in the internal chamber section, i.e., through holes in the internal chamber walls.

[0073] The materials may be formed such that chambers comprised by the chamber layer comprise a tube-like shape with an elliptical or round cross section. The materials may be formed such that at least one of the at least one chamber layer comprises a self-contained chamber that does not comprise a closed end in its longer extension. The materials may be formed such that at least one of the at least one chamber layer comprises a chamber comprising a toroidal or torus-like shape. The materials may be formed such that at least one of the at least one chamber layer comprises a three-part chamber comprising three sections of tube-like chambers that are joined at their respective ends by means of a Y- piece, wherein each section approximately resembles a semi-circle or a half ellipse. The materials may be formed such that at least one of the at least one chamber layer comprises a chamber resembling the shape of a section of a ring or a section an elliptical torus. The materials may be formed such that at least one of the at least one chamber layer comprises a tube-like chamber with closed ends that is bend in shape of a section of a circle or a section of an ellipse. The materials may be formed such that chambers of a respective chamber layer are interconnected by means of respective channels and / or holes. It will be understood that a chamber arrangement, e.g., a helmet, may comprise a plurality of differently shaped chambers, which may for example resemble the different shapes discussed above.

[0074] The method may be for manufacturing a wearable protective device, i.e., the protective device may be a wearable protective device. The method may be for manufacturing a helmet, i.e., the protective device may be a helmet. The helmet may be a sports helmet, preferably the helmet may be configured for skating, skiing, snowboarding, hiking, cycling, riding, (kite) surfing, mountaineering, climbing, paragliding, skydiving, rafting, canyoning, bungee jumping, bodyboarding, water skiing, wakeboarding, packrafting and / or kayaking. Additionally or alternatively, the helmet may generally be configured to be used on a means of transport, such as a scooter, bicycle, or motorbike. The helmet may be a motorbike helmet configured for riding a motorbike or scooter. Preferably, the helmet may be a bicycle helmet.

[0075] Alternatively, the method may be for manufacturing a protector, i.e., the protective device may be a protector, e.g., a knee protector, an elbow protector, a hip protector, a wrist protector, or a spine protector. The protector may be a protector for sports.

[0076] The protective device may be configured as personal protective equipment (PPE). The helmet may be configured for occupational health and safety.

[0077] The protective device may be configured for protection of objects, such as goods.

[0078] The method may further comprise providing a pressure indicator, configured to indicate a pressure within the chamber arrangement.

[0079] The method may further comprise providing a separating agent or separating layer. The separating agent or separating layer may be provided to one of the chamber layers, particularly an inner volume of one of the chamber layers.

[0080] The method may be a method for manufacturing a protective device as described above. Similarly, the protective device as described above may be manufactured in accordance with the above-described method.

[0081] The present invention is also defined by the following numbered embodiments.

[0082] Below, reference will be made to protective device embodiments. These embodiments are abbreviated by the letter "D" followed by a number. Whenever reference is herein made to "device embodiments", these embodiments are meant.

[0083] DI. An inflatable protective device comprising a chamber arrangement comprising a plurality of inflatable chambers, wherein the chambers are defined by chamber walls, and wherein at least external chamber walls of the chamber arrangement comprise a composite material, wherein the composite material comprises a textile material and a fluid-tight, elastic material that are permanently connected to each other, and wherein the composite material is arranged such that the fluid-tight, elastic material provides an inner surface of the respective external chamber walls.

[0084] D2. The device according to the preceding device embodiment, wherein the composite material comprises a layer of the textile material and at least one layer of the fluid-tight, elastic material. D3. The device according to any of the preceding device embodiments, wherein the fluid-tight, elastic material is an elastomer.

[0085] D4. The device according to any of the preceding device embodiments, wherein the fluid-tight, elastic material is a thermoplastic elastomer (TPE), preferably a thermoplastic polyurethane (TPU) or a thermoplastic copolyester (TPC).

[0086] D5. The device according to any of the preceding device embodiments, wherein the fluid-tight, elastic material is a synthetic film.

[0087] D6. The device according to the preceding device embodiment, wherein the fluid-tight, elastic material is a thermoplastic elastomer (TPE) film, preferably a thermoplastic polyurethane (TPU) or a thermoplastic copolyester (TPC) film.

[0088] D7. The device according to any of the preceding device embodiments, wherein the textile material is one of a knitted fabric, a crocheted fabric, or a woven fabric.

[0089] D8. The device according to the preceding device embodiment, wherein the knitted fabric is a weft knitted fabric or a warp knitted fabric.

[0090] D9. The device according to any of the preceding device embodiments, wherein the textile material is made of high density Polyethylen (HDPE), ultra-high-molecular-weight polyethylene (UHMMWPE), polyester, or polyamide, e.g., nylon or Kevlar.

[0091] DIO. The device according to any of the preceding device embodiments, wherein the composite material only comprises the textile material and the of fluid-tight, elastic material.

[0092] Dll. The device according to any of the preceding device embodiments, wherein the textile material and the fluid-tight, elastic material are materially bonded to each other to provide the permanent connection.

[0093] D12. The device according to any of the preceding device embodiments, wherein the textile material and the fluid-tight, elastic material are permanently connected to each other through the application of heat and pressure.

[0094] D13.The device according to any of the preceding device embodiments, wherein the textile material and the fluid-tight, elastic material are permanently connected to each other through HF-welding in twodimensional flat form.

[0095] D14. The device according to any of the preceding device embodiments, wherein the textile material and the fluid-tight, elastic material are permanently connected to each other through HF-welding in a 3-dimensional double curved form. D15. The device according to any of the preceding device embodiments, wherein the textile material and the fluid-tight, elastic material are permanently connected to each other through lamination.

[0096] D16. The device according to any of the preceding device embodiments, wherein the textile material and the fluid-tight, elastic material are permanently connected to each other through hot lamination.

[0097] D17. The device according to any of the preceding device embodiments, wherein the textile material and the fluid-tight, elastic material are permanently connected to each other through adhesion.

[0098] D18. The device according to any of the preceding device embodiments, wherein the composite material is further arranged such that the textile material provides an outer surface of the respective external chamber walls.

[0099] D19. The device according to any of the preceding device embodiments, wherein the composite material is further arranged such that the textile material provides an outer surface of the chamber arrangement.

[0100] D20. The device according to any of the preceding device embodiments, wherein the at least one chamber inner-wall comprises a constant hight.

[0101] D21. The device according to any of the preceding device embodiments, wherein the at least one chamber inner-wall comprises a variable hight.

[0102] D22. The device according to any of the preceding device embodiments, wherein the at least one chamber inner-wall is welded to the outer surface by 3-dimensional HF-welding.

[0103] D23. The device according to any of the preceding device embodiments, wherein the composite material of the external walls comprises a thickness of 0.1 mm to 2.5 mm, preferably, 0.3 mm to 2 mm, more preferably 0.5 mm to 1.5 mm.

[0104] D24. The device according to any of the preceding device embodiments, wherein the composite material is foldable.

[0105] D25. The device according to any of the preceding device embodiments, wherein the chamber arrangement is foldable in a deflated state.

[0106] D26. The device according to any of the preceding device embodiments, wherein the protective device is foldable in a deflated state. D27. The device according to any of the preceding device embodiments, wherein the protective device further comprises a valve, configured to provide access to the inflatable chambers in order to inflate / deflate said chambers.

[0107] D28. The device according to any of the preceding device embodiments, wherein the inflatable chambers are configured to withstand an internal pressure of at least up to 2 bar, preferably at least up to 3.5 bar, more preferably at least up to 5 bar.

[0108] D29. The device according to any of the preceding device embodiments, wherein the chamber arrangement comprises a weight of at most 800 g, preferably at most 400 g, preferably at most 200 g.

[0109] D30. The device according to any of the preceding device embodiments, wherein the device comprises a weight of at most 950 g, preferably at most 500 g, preferably at most 270 g.

[0110] D31. The device according to any of the preceding device embodiments which, when inflated, rests on a head only with its flat material side against the head.

[0111] D32. The device according to any of the preceding device embodiments that can be folded several times in all directions when deflated.

[0112] D33. The device according to any of the preceding device embodiments whose shape is created from at least 1 to 3 large-area air chambers, which are connectable by at least one hole or channel.

[0113] D34. The device according to any of the preceding device embodiments wherein 2 or more chambers are superimposed and / or connected so that a weak point is covered in a complementary manner, so that the week point of one chamber is covered by a part of one of the other chambers.

[0114] D35. The device according to any of the preceding device embodiments wherein the weak point is at least one of a welding point, a seam or an area between fingers.

[0115] D36. The outer chamber has the main shaping effect while the possible two air chambers inside only append to the main chamber.

[0116] D37. The device according to any of the preceding device embodiments wherein overlapping fingers are configured to be laid in an at least one directional curved shape.

[0117] D38. The device according to any of the preceding device embodiments wherein the overlapping fingers form a substantially half ball shaped form when not inflated.

[0118] D39. The device according to any of the preceding device embodiments wherein fixed points located on the sides form a 3D shape of the protective device when inflated. D40. The device according to any of the preceding device embodiments wherein the at least 2 sides comprise at least one incision each and are configured to be circular-like welded at their ends.

[0119] D41. The device according to any of the preceding device embodiments wherein the outer chambers are configured to form a 3D shape provided by at least one air chamber.

[0120] D42. The device according to any of the preceding device embodiments wherein welded walls within an air chamber prevent ball-like inflation of the chamber arrangement to hold the outer walls of the chamber arrangement in form.

[0121] D43. The device according to any of the preceding device embodiments wherein the welded inner walls create areas that bend more easily and are conducive to the overall shape by varying the height of these walls.

[0122] D44. The device according to any of the preceding device embodiments wherein joining of all fingers on the left and right sides allows additional forcing of the air cushions into the desired shape, regardless of the method of joining.

[0123] D45. The device according to any one of the device embodiments wherein the method of joining the fingers is interlocking.

[0124] D46. The device according to any one of the device embodiments wherein the method of joining the fingers is riveting.

[0125] D47. The device according to any one of the device embodiments wherein cutouts are positioned in the weld seams either at the end of the finger or on the side of the finger.

[0126] D48. The device according to any one of the device embodiments wherein the cutouts have an elliptical or round form.

[0127] D49. The device according to the ultimate device embodiment wherein the cutouts have a diameter of at least 1 mm, preferably 2 mm to 7mm, more preferably 4 mm to 5 mm.

[0128] D50. The device according to any of the preceding device embodiments wherein an additional material surface extends at least two fingers from the end or the side of the finger.

[0129] D51. The device according to any one of the device embodiments wherein the additional material surface connects on the outside of the chamber arrangement different fingers.

[0130] D52. The device according to any one of the device embodiments wherein the additional material surface connects fingers from one lateral side to the other lateral side. D53. The device according to any one of the device embodiments wherein the additional material surface covers areas without an air chamber such as a welding point or the space between fingers.

[0131] D54. The device according to any one of the device embodiments wherein the additional material surface supports the form of the device by pulling the fingers together.

[0132] D55. The device according to any of the preceding device embodiments wherein an elongated hole can be left in the outer material at the welding surface of the inner walls so that the fluid-tight, elastic material side of the bar looks out, the fluid-tight, elastic material being preferably TPU.

[0133] D56. The device according to any of the preceding device embodiments comprises a hole in the circular weld from configured to serve as a ventilation hole

[0134] D57. The device according to any of the preceding device embodiments, wherein each of the plurality of inflatable chambers are fluidly connected to at least one adjacent chamber through a respective hole and / or channel.

[0135] D58. The device according to any of the preceding device embodiments, wherein the plurality of inflatable chambers are fluidly interconnected.

[0136] D59. The device according to any of the preceding device embodiments, wherein the chamber arrangement comprises a single chamber layer.

[0137] D60. The device according to any of the preceding device embodiments, excluding the features of the preceding embodiment, wherein the chamber arrangement comprises a plurality of chamber layers.

[0138] D61. The device according to any of the preceding device embodiments, wherein the chamber arrangement comprises at most two chamber layers.

[0139] D62. The device according to any of the preceding device embodiments, wherein the chamber layers are arranged to be stacked on top of each other in a proximal-to-distal direction.

[0140] D63. The device according to any of the preceding device embodiments, wherein the chamber layers are arranged such that chambers of adjacent chamber layers at least partially overlap in a proximal-to-distal direction.

[0141] D64. The device according to any of the preceding device embodiments, wherein weld joints located within a chamber layer overlap with at least one chamber of an adjacent chamber layer along the proximal-to-distal direction. D65. The device according to any of the preceding device embodiments, wherein weld joints of located within a chamber layer do not overlap with weld joins within an adjacent chamber layer along the proximal-to-distal direction.

[0142] D66. The helmet according to any of the preceding helmet embodiments, wherein the plurality of chamber layers is fluidly connected to each other.

[0143] D67. The device according to any of the preceding device embodiments, wherein chambers within one chamber layer are fluidly connected to each other.

[0144] D68. The device according to any of the preceding device embodiments, wherein the chamber arrangement comprises at least one internal chamber section, and wherein internal walls of adjacent chambers of neighbouring chamber layers are provided through a respective internal chamber section.

[0145] D69. The device according to any one of the preceding device embodiments, wherein the device comprises at least two regions (101, 102) from which one covers at least one of the front region, the upper region and the rear region of a head and another one can cover the at least one lateral region of the head.

[0146] D70. The device according to any one of the preceding device embodiments wherein a chamber arrangement comprising of at least two outer walls (22) connected to at least one inner wall (129) by welding lines (26) protects the central region (101) covering at least one of the front region, the upper region and the rear region of the head.

[0147] D71. The device according to any one of the preceding device embodiments wherein a chamber arrangement (LI) with inner walls (129) and outer walls (22) is connected to each other at the welding lines (26).

[0148] D72. The device according to any one of the preceding device embodiments wherein in region (102) fingers (34) extend from region (101) in a lateral area of the device.

[0149] D73. The device according to any one of the preceding device embodiments wherein the fingers comprise a chamber arrangement (LI) comprising at least two outer wall (22) and at least comprises one inner wall (129) and in which the walls are connected to each other at the welding lines (26).

[0150] D74. The device according to any one of the preceding device embodiments, wherein the at least one internal chamber section does not provide any external chamber wall.

[0151] D75. The device according to any one of the device embodiments, wherein the at least one internal chamber section further provides a portion of the external chamber wall(s). D76. The device according to any of the preceding device embodiments, wherein the chamber arrangement comprises a single internal chamber section.

[0152] D77. The device according to any of the preceding device embodiments, wherein the at least one internal chamber section comprises the fluid-tight, elastic material.

[0153] D78. The device according to any of the preceding device embodiments, wherein the at least one internal chamber section comprises the textile material.

[0154] D79. The device according to any of the preceding device embodiments, wherein the at least one internal chamber section comprises an internal composite material comprising the fluid-tight, elastic material and the textile material, which are permanently connected to each other.

[0155] D80. The device according to any one of the preceding device embodiments, wherein the internal composite material comprises the textile material sandwiched between the fluid- tight, elastic material, wherein the materials are permanently connected to each other.

[0156] D81. The device according to any of the preceding device embodiments, wherein the chamber arrangement comprises at least one external chamber section formed of the composite material constituting the external chamber walls.

[0157] D82. The device according to any one of the preceding device embodiments, wherein the chamber arrangement comprises at most two external chamber sections.

[0158] D83. The device according to any of the preceding device embodiments, wherein the chamber arrangement comprises a single external chamber section.

[0159] D84. The device according to any of the preceding device embodiments, wherein a collection of at least one chamber section comprising at least one external chamber section and optionally at least one internal chamber section is welded together to provide the chamber arrangement.

[0160] D85. The device according to any one of the preceding device embodiments, wherein the collection of at least one chamber section comprises a plurality of external chamber sections.

[0161] D86. The device according to any one of the preceding device embodiments, wherein the plurality of external chamber sections comprises different shapes.

[0162] D87. The device according to any of the preceding device embodiments, wherein the collection of at least one chamber section comprises one internal chamber section. D88. The device according to any of the preceding device embodiments, wherein welding joints of the external chamber section(s) are located between respective neighbouring chambers of a chamber layer and at an outer rim of the respective chamber arrangement.

[0163] D89. The device according to any of the preceding device embodiments, wherein the plurality of inflatable chambers comprise a tube-like shape with an elliptical or round cross section.

[0164] D90. The device according to any of the preceding device embodiments, wherein the plurality of inflatable chambers comprise at least one finger that are joined together with another finger in such a way that the device takes on a double-curved shape and becomes semi-circular or helmet-shaped.

[0165] D91. The device according to any of the preceding device embodiments, wherein the plurality of inflatable chambers comprises a split cross section, wherein a distal portion of the plurality of chambers comprises a different cross-section to a proximal portion of the plurality of chambers.

[0166] D92. The device according to any of the preceding device embodiments, wherein at least one of the inflatable chambers comprises a split cross section, wherein the split cross section is capable of withstanding a filling pressure of at least 2 bar, preferably 3 bar, more preferably 5 bar.

[0167] D93. The device according to any one of the preceding device embodiments, wherein the distal portion or the proximal portion comprises a cross-section resembling a circular segment or an elliptical segment.

[0168] D94. The device according to any one of the preceding device embodiments, wherein the respective other portion comprises a cross section resembling a polygonal, preferably hexagonal, segment.

[0169] D95. The device according to any of the preceding device embodiments, wherein at least one of the plurality of inflatable chambers is a self-contained chamber that does not comprise a closed end in its longest extension.

[0170] D96. The device according to any of the preceding device embodiments, wherein at least one of the plurality of inflatable chambers is a chamber comprising a toroidal or torus-like shape.

[0171] D97. The device according to any of the preceding device embodiments, wherein at least one of the plurality of inflatable chambers is a three-part chamber comprising three sections of tube-like chambers that are joined at their respective ends by means of a Y- piece, wherein each section approximately resembles a semi-circle or a half ellipse. D98. The device according to any of the preceding device embodiments, wherein at least one of the plurality of inflatable chambers is a chamber resembling the shape of a section of a ring or a section an elliptical torus.

[0172] D99. The device according to any of the preceding device embodiments, wherein at least one of the plurality of inflatable chambers is a tube-like chamber with closed ends that is bend in shape of a section of a circle or a section of an ellipse.

[0173] D100. The device according to any of the preceding device embodiments, wherein the upper 2 fingers and the lower 2-4 fingers are joined under the apex of a hemisphere, creating a ring that can absorb all stresses of the fingers without forming a flat cushion thus defining the final shape of the device.

[0174] D101. The device according to any of the preceding device embodiments, wherein the fingers are joined in such a way, that they bend in lateral direction to support the semi hemispherical form.

[0175] D102. The device according to any one of the preceding device embodiments wherein the distance of two neighbouring air chambers is minimised by sewing their welding seams together, preferable on the longitudinal and / or end sides of the tubes.

[0176] D103. The device according to any of the preceding device embodiments, wherein the device further comprises fixation means.

[0177] D104. The device according to any one of the preceding device embodiments, wherein the fixation means comprise at least one webbing strap.

[0178] D105. The device according to any of the preceding device embodiments, wherein the fixation means comprise a fastener.

[0179] D106. The device according to any of the preceding device embodiments, wherein the fixation means comprise a quick-release fastener.

[0180] D107. The device according to any of the preceding device embodiments, wherein the fixation means comprise an adjustment means, configured to adjust the fixations means in length and / or size.

[0181] D108. The device according to any of the preceding device embodiments, wherein the protective device is a wearable protective device.

[0182] D109. The device according to any of the preceding device embodiments, wherein the protective device is a helmet. DI 10. The device according to any of the preceding device embodiments, wherein the helmet is covered with a textile cover, which is replaceable and is attached to the helmet structure.

[0183] Dill. The device according to any of the preceding device embodiments, wherein the helmet is covered with a textile cover, which is replaceable and can be attached to the helmet structure by a Velcro fastener.

[0184] DI 12. The device according to any one of the preceding device embodiments, wherein the helmet is a sports helmet.

[0185] DI 13. The device according to any of the preceding device embodiments, wherein the helmet is configured for at least one or a plurality of skating, skiing, snowboarding, hiking, cycling, riding, (kite) surfing, mountaineering, climbing, paragliding, skydiving, rafting, canyoning, bungee jumping, bodyboarding, water skiing, wakeboarding, packrafting and / or kayaking.

[0186] DI 14. The device according to any of the preceding device embodiments, wherein the device is a bicycle helmet.

[0187] DI 15. The device according to any of the preceding device embodiments, wherein the helmet is configured to be used on a means of transport, such as a scooter, bicycle, or motorbike.

[0188] DI 16. The device according to any of the preceding device embodiments, wherein the helmet is a motorbike helmet configured for riding a motorbike or scooter.

[0189] DI 17. The device according to any of the preceding device embodiments, wherein the fixation means are configured for fixing the helmet to a wearer's head when in use.

[0190] DI 18. The device according to any of the preceding device embodiments excluding embodiments D109 to D117, wherein the protective device is a protector, e.g., a knee protector, an elbow protector, a hip protector, a wrist protector, or a spine protector.

[0191] DI 19. The device according to the preceding device embodiment, wherein the protector is a protector for sports.

[0192] D120. The device according to any of the preceding device embodiments, wherein the protective device is configured as personal protective equipment (PPE).

[0193] D121. The device according to any of the preceding device embodiments, wherein the protective device is configured for occupational health and safety. D122. The device according to any of the preceding device embodiments excluding embodiments D68 to D76, wherein the protective device is configured for protection of objects, such as goods.

[0194] D123. The device according to any of the preceding device embodiments, wherein the device further comprises a pressure indicator, configured to indicate a pressure within the chamber arrangement.

[0195] D124. The device according to any of the preceding device embodiments, wherein an adaptation layer is provided as the most proximal chamber layer of the chamber arrangement and wherein said adaptation layer is not fluidly connected to any other chamber layer.

[0196] D125. The device according to any one of the preceding device embodiments, wherein the adaption layer is configured to hold a pressure of less than 0.5 bar, preferably less than 0.3 bar.

[0197] D126. The device according to any of the preceding device embodiments, wherein the adaptation layer is pressurized to less than 0.5 bar, preferably less than 0.3 bar when in use.

[0198] D127. The device according to any of the preceding device embodiments, wherein all other chamber layers of the chamber arrangement are fluidly connected to each other.

[0199] D128. The device according to any of the preceding device embodiments, wherein the chamber arrangement comprises two chamber layers that share an internal chamber section and wherein the chamber section provides the internal chamber walls and additionally, a portion of the external chamber walls due to a difference in shape of the two chamber layers.

[0200] D129. The device according to any of the preceding device embodiments, wherein chambers within each chamber layer are defined through respective weld joints in the form of weld points.

[0201] D130. The device according to any of the preceding device embodiments, wherein the chamber layers are fluidly connected via a single hole.

[0202] D131. The device according to any of the preceding device embodiments, wherein the distal chamber layer comprises a plurality of parallel fingers that are mirror-symmetrically arranged to an axis perpendicular to the fingers, wherein the fingers on either side of the axis may each respectively be joined in at least one point, thereby creating a curvature of the chamber assembly. D132. The device according to any of the preceding device embodiments, wherein the internal chamber section may comprise the internal composite material according to embodiment D44.

[0203] D133. The device according to the preceding device embodiment, wherein chambers are formed by double-curved shape walls through 3D welding preferable 3D HF welding.

[0204] D134. The device according to the preceding device embodiment, wherein chambers are forced into a preferred shape of the device by forcing the air cushions together by defining connections.

[0205] D135. The device according to any one of the preceding device embodiments wherein a connection is accomplished by at least one of sewing, interlocking, welding or rivets.

[0206] D136. The device according to the preceding device embodiment, wherein additional chambers are fitted inside the helmet in such a way they cover welding points or areas between two chambers which are not provided with any other chamber.

[0207] D137. The device according to any one of the preceding device embodiments wherein the additional chambers are connected with the helmet via a lateral connection to the helmet and wherein the lateral connection is made of the same material as the helmet.

[0208] D138. The device according to any one of the preceding device embodiments wherein the additional chambers are connected with the device through at least one hole or channel made of the same material as the device and are physically connected at at least one point.

[0209] D139. The device according to the preceding device embodiment wherein the additional chambers are connected with the device through welding.

[0210] D140. The device according to the penultimate device embodiment wherein the additional chambers are connected with the device through at least two plastic parts which clip into each other.

[0211] D141. The device according to any one of the preceding device embodiments wherein the chambers are connected with the helmet through at least one hole or channel.

[0212] D142. The device according to any one of the preceding device embodiments wherein the chambers are physically connected at at least one point.

[0213] D143. The device according to any of the preceding device embodiments, wherein the protective device is manufactured according to any of the preceding method embodiments. Below, reference will be made to method embodiments. These embodiments are abbreviated by the letter "M" followed by a number. Whenever reference is herein made to "method embodiments", these embodiments are meant.

[0214] Ml. A method for manufacturing an inflatable protective device comprising a chamber arrangement of inflatable chambers, the method comprising providing at least two different materials; forming the materials; joining the materials to provide a composite material; cutting and / or punching the formed and joined materials to provide at least one external chamber section of formed composite material; welding together a collection of at least one chamber section, comprising at least one external chamber section of formed composite material to provide the chamber arrangement.

[0215] M2. The method according to the preceding method embodiment, wherein the step of forming the materials precedes the step of joining the materials to provide a composite material.

[0216] M3. The method according to the penultimate method embodiment, wherein the step of joining the materials to provide a composite material precedes the step forming the materials.

[0217] M4. The method according to Ml, wherein the step of forming the materials and the step of joining the materials to provide a composite material are at least partially performed simultaneously.

[0218] M5. The method according to any of the preceding method embodiments, wherein forming the materials comprises forming the materials using a respective mold or forming die.

[0219] M6. The method according to the preceding method embodiment, wherein the at least two materials are layered and subsequently pressed or drawn into or onto the mold or forming die.

[0220] M7. The method according to the penultimate method embodiment, wherein at least one of the materials is pre-shaped to roughly approximate a desired overall shape.

[0221] M8. The method according to any of the 3 preceding method embodiments, wherein joining the materials comprises heating the mold or forming die.

[0222] M9. The method according to the preceding method embodiment, wherein the mold or forming die is heated prior to forming of the materials. MIO. The method according to the penultimate method embodiment, wherein the mold or forming die is heated after forming of the materials.

[0223] That is, the mold or forming die may only be heated once the material is already lying against a respective surface of the mold / forming die resembling the desired shape

[0224] Mil. The method according to any of the 5 preceding method embodiments, wherein the mold or forming die is made from metal, preferably aluminium or steel.

[0225] M12. The method according to any of the preceding method embodiments, wherein joining the materials comprises application of heat and pressure.

[0226] M13. The method according to any of the preceding method embodiments, wherein joining the materials comprises materially bonding the materials to each other to provide a permanent connection.

[0227] M14. The method according to any of the preceding method embodiments, wherein joining the materials comprises laminating the materials.

[0228] M15. The method according to any of the preceding method embodiments, wherein joining the materials comprises hot laminating the materials.

[0229] M16. The method according to any of the preceding method embodiments, wherein joining the materials comprises adhesion of the materials.

[0230] M17. The method according to any of the preceding method embodiments, wherein forming the materials comprises forming by thermoforming or by forming based on active media.

[0231] M18. The method according to the preceding method embodiment, wherein the active media comprises pressurized fluid.

[0232] M19. The method according to any of the 2 preceding method embodiments, wherein the active media comprises pressurized air, gas and / or steam.

[0233] M20. The method according to any of the 3 preceding method embodiments, wherein the method comprises providing heated active media for joining the materials.

[0234] M21. The method according to any of the 4 preceding method embodiments, wherein the method comprises providing heated active media for forming the materials.

[0235] M22. The method according to any of the preceding method embodiments, wherein the at least two different materials are provided as layers of respective materials, e.g., sheets of respective materials. M23. The method according to any of the preceding method embodiments, wherein the materials comprise a fluid-tight, elastic material.

[0236] M24. The method according to the preceding method embodiment, wherein the fluid- tight, elastic material is a thermoplastic elastomer (TPE), preferably a thermoplastic polyurethane (TPU) or a thermoplastic copolyester (TPC).

[0237] M25. The method according to any of the 2 preceding method embodiments, wherein the fluid-tight, elastic material is a synthetic film.

[0238] M26. The method according to any of the 3 preceding method embodiments, wherein the fluid-tight, elastic material is a thermoplastic elastomer (TPE) film, preferably a thermoplastic polyurethane (TPU) or a thermoplastic copolyester (TPC) film.

[0239] M27. The method according to any of the 4 preceding method embodiments, wherein the fluid-tight, elastic material is provided as a layer comprising a thickness of 0.05 mm to 0.8 mm, preferably, 0.08 mm to 0.5 mm, more preferably 0.1 mm to 0.2mm.

[0240] M28. The method according to any of the preceding method embodiments, wherein the materials comprise a textile material.

[0241] M29. The method according to the preceding method embodiment, wherein the textile material is one of a knitted fabric, a crocheted fabric, or a woven fabric.

[0242] M30. The method according to the preceding method embodiment, wherein the knitted fabric is a weft knitted fabric or a warp knitted fabric.

[0243] M31. The method according to any of the 3 preceding method embodiments, wherein the textile material is made of high density Polyethylen (HDPE), ultra-high-molecular-weight polyethylene (UHMMWPE), polyester, or polyamide, e.g., Nylon or Kevlar.

[0244] M32. The method according to any of the 4 preceding method embodiments, wherein the textile material is provided as a layer comprising a thickness of 0.1 mm to 3 mm, preferably, 0.5 mm to 2.5 mm more preferably 1 mm to 2 mm.

[0245] M33. The method according to any of the preceding method embodiments, wherein the textile material and / or the composite material is treated with water repellent.

[0246] M34. The method according to any of the 7 preceding method embodiments, wherein the textile material and / or the composite material is treated with an UV inhibitor or UV protectant. M35. The method according to any of the preceding method embodiments, wherein the composite material of the at least one external chamber section comprises a thickness of 0.1 mm to 3 mm, preferably, 0.5 mm to 2 mm, more preferably 0.7 mm to 1.6 mm.

[0247] M36. The method according to any of the preceding method embodiments, wherein the composite material is foldable.

[0248] M37. The method according to any of the preceding method embodiments, wherein the chamber arrangement is foldable in a deflated state.

[0249] M38. The method according to any of the preceding method embodiments, wherein the protective device is foldable in a deflated state.

[0250] M39. The method according to any of the preceding method embodiments, wherein cutting and / or punching the formed and joined materials comprises utilising a die.

[0251] M40. The method according to the preceding method embodiment and with the features of M5, wherein the forming die and the die are provided as a single die.

[0252] M41. The method according to any of the preceding method embodiments, wherein the steps of providing at least two different materials, forming the materials, joining the materials to provide a composite material, and cutting and / or punching the formed and joined materials to provide at least one external chamber section of formed composite material are repeated.

[0253] M42. The method according to any of the preceding method embodiments, wherein welding comprises high-frequency welding.

[0254] M43. The method according to any of the preceding method embodiments, wherein the method further comprises welding a valve into the chamber arrangement configured to enable inflating and deflating of connected chambers.

[0255] M44. The method according to any of the preceding method embodiments, wherein the method further comprises welding a valve into one of the at least one external chamber section configured to enable inflating and deflating of connected chambers.

[0256] M45. The method according to any of the preceding method embodiments, wherein the method further comprises designing the protective device.

[0257] M46. The method according to the preceding method embodiment, wherein designing the protective device comprises providing a digital model of the protective device, preferably by using a computer-aided design (CAD) software. M47. The method according to any of the 2 preceding method embodiments, wherein the designing the protective device further comprises simulating a geometry of the protective device.

[0258] M48. The method according to any of the 3 preceding method embodiments, wherein the designing the protective device further comprises simulating an appearance of the protective device in an inflated state.

[0259] M49. The method according to any of the 4 preceding method embodiments and with the features of M5, wherein the method further comprises providing at least one mold or forming die based on the designed protective device.

[0260] M50. The method according to any of the preceding method embodiments, wherein the chamber arrangement comprises a single chamber layer and wherein chambers comprised by the chamber arrangement do not overlap in a proximal to distal direction.

[0261] M51. The method according to any of the preceding method embodiments, wherein the chamber arrangement comprises a plurality of chamber layers.

[0262] M52. The method according to the preceding method embodiment, wherein the plurality of chamber layers are arranged such that each chamber layer comprises at least one chamber that at least partially overlaps with a chamber of an adjacent layer in the proximal-to-distal direction.

[0263] M53. The method according to any of the 2 preceding method embodiments, wherein the plurality of chamber layers are stacked on top of each other in a proximal-to-distal direction.

[0264] M54. The method according to any of the 3 preceding method embodiments, wherein the plurality of chamber layers are arranged such that chambers of adjacent chamber layers at least partially overlap in a proximal-to-distal direction.

[0265] M55. The method according to any of the 4 preceding method embodiments, wherein adjacent chamber layers are arranged such that weld joints within a chamber layer overlap with at least one chamber of an adjacent chamber layer in the proximal-to-distal direction.

[0266] M56. The method according to any of the 5 preceding method embodiments, wherein adjacent chamber layers are arranged such that weld joints located within a chamber layer do not overlap with weld joints within an adjacent chamber layer in the proximal-to-distal direction.

[0267] M57. The method according to any of the 6 preceding method embodiments, wherein at least one chamber of a chamber layer is fluidly connected to a chamber of an adjacent chamber layer. M58. The method according to any of the 8 preceding method embodiments, wherein chambers within one chamber layer are fluidly connected to each other.

[0268] M59. The method according to any of the 8 preceding method embodiments, wherein the method further comprises providing at least one internal chamber section.

[0269] M60. The method according to the preceding method embodiment, wherein the collection of at least one chamber section comprises a single internal chamber section.

[0270] M61. The method according to the penultimate method embodiment, wherein the collection of at least one chamber section comprises at least one internal chamber section.

[0271] M62. The method according to any of the 3 preceding method embodiments, wherein providing the at least one chamber section comprises providing internal section material.

[0272] M63. The method according to the preceding method embodiment, wherein the internal section material comprises a fluid-tight, elastic material.

[0273] M64. The method according to the preceding method embodiment, wherein the fluid- tight, elastic material is the same as comprised by the composite material of the external chamber section.

[0274] M65. The method according to any of the 2 preceding method embodiments, wherein the internal section material comprises a textile material.

[0275] M66. The method according to the preceding method embodiment, wherein the textile material is the same as comprised by the composite material of the external chamber section.

[0276] M67. The method according to any of the preceding method embodiments and with the features of M63 and M65, wherein providing the at least one chamber section comprises joining the fluid-tight, elastic material and the textile material such that a layer of textile material is sandwiched between layers of fluid-tight, elastic material.

[0277] M68. The method according to any of the 6 preceding method embodiments, wherein providing the at least one chamber section comprises cutting and / or punching the internal section material.

[0278] M69. The method according to any of the preceding method embodiments, wherein the collection of at least one chamber section comprises at most two external chamber sections of formed composite material to provide the chamber arrangement. M70. The method according to any of the preceding method embodiments, wherein the collection of at least one chamber section comprises a plurality of external chamber sections and wherein the external chamber sections comprise different shapes.

[0279] M71. The method according to any of the preceding method embodiments, wherein welding joints of the collection of at least one chamber section are located between adjacent chambers within a chamber layer and at an outer rim of the chamber arrangement.

[0280] M72. The method according to any of the preceding method embodiments, wherein welding joints of a chamber layer are located within a convex surface running through the chamber arrangement.

[0281] M73. The method according to any of the preceding method embodiments, wherein the method further comprises attaching fixation means to the chamber arrangement.

[0282] M74. The method according to any of the preceding method embodiments, wherein the inflatable chambers are configured to withstand an internal pressure of at least up to 2 bar, preferably at least up to 3.5 bar, more preferably at least up to 5 bar.

[0283] M75. The method according to any of the preceding method embodiments, wherein each of the plurality of inflatable chambers is fluidly connected to at least one adjacent chamber through a respective hole and / or channel.

[0284] M76. The method according to any of the preceding method embodiments, wherein the plurality of inflatable chambers are fluidly interconnected.

[0285] M77. The method according to any of the preceding method embodiments, wherein the materials are formed such that chambers comprised by the chamber layer comprise a tubelike shape with an elliptical or round cross section.

[0286] M78. The method according to the preceding method embodiment, wherein the materials are formed such that at least one of the at least one chamber layer comprises a self- contained chamber that does not comprise a closed end in its longer extension.

[0287] M79. The method according to any of the 2 preceding method embodiments, wherein the materials are formed such that at least one of the at least one chamber layer comprises a chamber comprising a toroidal or torus-like shape.

[0288] M80. The method according to any of the 3 preceding method embodiments, wherein the materials are formed such that at least one of the at least one chamber layer comprises a three-part chamber comprising three sections of tube-like chambers that are joined at their respective ends by means of a Y-piece, wherein each section approximately resembles a semi-circle or a half ellipse. M81. The method according to any of the 4 preceding method embodiments, wherein the materials are formed such that at least one of the at least one chamber layer comprises a chamber resembling the shape of a section of a ring or a section an elliptical torus.

[0289] M82. The method according to any of the preceding method embodiments, wherein the materials are formed such that at least one of the at least one chamber layer comprises a tube-like chamber with closed ends that is bend in shape of a section of a circle or a section of an ellipse.

[0290] M83. The method according to any of the preceding method embodiments, wherein the materials are formed such that chambers of a respective chamber layer are interconnected by means of respective channels and / or holes.

[0291] M84. The method according to any of the preceding method embodiments, wherein the protective device is a wearable protective device.

[0292] M85. The method according to any of the preceding method embodiments, wherein the protective device is a helmet.

[0293] M86. The method according to the preceding method embodiment, wherein the helmet is a sports helmet.

[0294] M87. The method according to any of the 2 preceding method embodiments, wherein the helmet is configured for skating, skiing, snowboarding, hiking, cycling, riding, (kite) surfing, mountaineering, climbing, paragliding, skydiving, rafting, canyoning, bungee jumping, bodyboarding, water skiing, wakeboarding, packrafting and / or kayaking.

[0295] M88. The method according to any of the 3 preceding method embodiments, wherein the helmet is a bicycle helmet.

[0296] M89. The method according to any of the 4 preceding method embodiments, wherein the helmet is configured to be used on a means of transport, such as a scooter, bicycle, or motorbike.

[0297] M90. The method according to any of the 5 preceding method embodiments, wherein the helmet is a motorbike helmet configured for riding a motorbike or scooter.

[0298] M91. The method according to any of the preceding method embodiments excluding embodiments M85 to M90, wherein the protective device is a protector, e.g., a knee protector, an elbow protector, a hip protector, a wrist protector, or a spine protector.

[0299] M92. The method according to the preceding method embodiment, wherein the protector is a protector for sports. M93. The method according to any of the preceding method embodiments, wherein the protective device is configured as personal protective equipment (PPE).

[0300] M94. The method according to any of the preceding method embodiments, wherein the helmet is configured for occupational health and safety.

[0301] M95. The method according to any of the preceding method embodiments excluding embodiments M85 to M94, wherein the protective device is configured for protection of objects, such as goods.

[0302] M96. The method according to any of the preceding method embodiments, wherein the method further comprises providing a pressure indicator, configured to indicate a pressure within the chamber arrangement.

[0303] M97. The method according to any of the preceding method embodiments, wherein the protective device is according to any of the preceding device embodiments.

[0304] M98. The method according to any of the preceding method embodiments, wherein the method further comprises providing a separating agent or separating layer.

[0305] M99. The method according to the preceding method embodiment and with the features of M51, wherein the separating agent or separating layer is provided to one of the chamber layers, particularly an inner volume of one of the chamber layers.

[0306] Embodiments of the present invention will now be described with reference to the accompanying drawings. These embodiments should only exemplify, but not limit, the present invention.

[0307] Brief description of the drawings

[0308] Figs, la to 1c depict examples of a general manufacturing method according to the present invention;

[0309] Figs. 2a to 2c illustrating exemplary steps of a manufacturing method according to the present invention;

[0310] Figs. 3a to 3c illustrate exemplary cross sections of chamber arrangements;

[0311] Figs. 4a to 4f illustrate an exemplary embodiment of a chamber arrangement comprising a single chamber layer;

[0312] Figs. 5a to 5e illustrate an exemplary embodiment of a chamber arrangement comprising two chamber layers;

[0313] Figs. 6a to 6b illustrate another exemplary embodiment of a chamber arrangement comprising two chamber layers;

[0314] Figs. 7a, 7b illustrate shapes of chamber sections and welding points for the chamber arrangement shown in Figs. 6a to 6c. Figs. 8a to 8d illustrate another exemplary embodiment of a chamber arrangement formed by fixing fingers together. The chamber arrangement comprises two chamber layers which are interconnected by channels or holes.

[0315] Figs. 9a to 9e illustrate another exemplary embodiment of a chamber arrangement comprising an exemplary form of the inner chambers and the method of fixing the inner layer to the outer layer.

[0316] Figs. 10 illustrate shapes of chamber sections and welding points for the chamber arrangement shown in Figs. 6a to 6b.

[0317] Referral numbers in an overview

[0318] 1 = textile material

[0319] 2 = fluid-tight elastic material

[0320] 4 = composite material

[0321] 18 = chamber arrangement

[0322] 20 = plurality of inflatable chambers I chamber

[0323] 22 = external chamber walls

[0324] 22b = inner surface of external chamber wall

[0325] 22a = outer surface of external chamber wall

[0326] 23 = channel

[0327] 24 = hole

[0328] 26 = welding joint

[0329] 28 = internal chamber section

[0330] 30 = external chamber section

[0331] 34 = fingers

[0332] 36 = inlet valve

[0333] 37 = single valve

[0334] 38 = outlet valve

[0335] 101 = middle part helmet

[0336] 102 = side parts of helmet

[0337] 111 = hole for rivets

[0338] 112 = rivets

[0339] 114-1 = clip masculine

[0340] 114-2 = clip feminine

[0341] 114 = clip joint of 2 chambers

[0342] 113 = interlocking seam

[0343] 120 = additional chamber

[0344] 124 = hole welding joint I fluidly connected

[0345] 125 = possible ventilation hole

[0346] 126 = outer welding joints

[0347] 126-1 = welding joint of 2 chambers

[0348] 129 = inner walls

[0349] 130 = welded inner layer

[0350] 130-1 = weldable cutouts in the layer 134 = end of finger

[0351] 134-1 = side of finger

[0352] 134-2 = foremost fingers

[0353] 134-3 =trailing fingers

[0354] LI = Layer 1 inside L2 = Layer 2 outside Al = Axis 1 symmetry axis A2 = Axis 2 separation axis middle part to fingers section

[0355] Detailed description of embodiments

[0356] It is noted that not all the drawings carry all the reference signs. Instead, in some of the drawings, some of the reference signs have been omitted for the sake of brevity and simplicity of the illustration. Embodiments of the present invention will now be described with reference to the accompanying drawings.

[0357] Throughout the description, the terms proximal and distal will be used. Distal denotes a section that is further away from an inside of the protective device, e.g., helmet, than another section (i.e., further away than a more proximal section). That is, in the embodiment depicted in Fig. 3b the second chamber layer L2 is distal to the first chamber layer LI. in other words, the proximal-to-distal direction is defined as the radial direction from an inner portion of the protective device to an outer portion of the protective device, wherein the inner portion may generally be configured to receive a body part or object when in use, e.g., a wearer's head in case of a helmet. Consequently, a proximal section may also be referred to as an "inner" section and a distal section may also be referred to as an "outer" section.

[0358] The present invention generally relates to an inflatable protective device that comprises a chamber arrangement comprising plurality of inflatable chambers defined by respective chamber walls. In other words, the chambers may comprise chamber walls that define the chamber itself and particularly an inner volume thereof. Further, at least external chamber walls of the chamber arrangement comprise a composite material and preferably may be made of the composite material. Preferably all external chamber walls may comprise a type of composite material.

[0359] Said composite material comprises a textile material and a fluid-tight, elastic material that are permanently connected to each other. In particular, the materials may be materially bonded to each other, e.g., through welding, lamination, and / or adhesion.

[0360] Furthermore, the composite material is arranged such that the fluid-tight, elastic material provides an inner surface of the external chamber walls. Thus, the textile material may for example serve to protect the fluid-tight, elastic material from being damaged. Additionally, the textile layer may also limit an extension of the fluid-tight, elastic material when the chamber is inflated, i.e., pressurized. Generally, the fluid-tight, elastic material may for example be a synthetic film, preferably a thermoplastic elastomer (TPE) film, preferably a thermoplastic polyurethane (TPU) or thermoplastic copolymer (TPC) film. The textile layer may generally be a knitted fabric, e.g., a weft knitted fabric or a warp knitted fabric, a crocheted fabric, or a woven fabric. The textile layer may for example be made of high density Polyethylen (HDPE), ultra-high- molecular-weight polyethylene (UHMMWPE), polyester, or polyamide, e.g., nylon or Kevlar. A textile layer made of polyester or polyamide, particularly nylon, may be preferred. The textile layer may be impermeable to water, e.g., based on the weave or material, and / or the textile layer and / or the material it is made of may be treated with water repellent. This may advantageously prevent the textile layer from soaking up too much water for example during rain, which may increase weight of the protective device and could also potentially alter material properties. Furthermore, the textile layer and / or the material it is made of may be treated with a UV inhibitor or UV protectant., e.g., a UV-inhibiting coating. This may advantageously reduce material deterioration due to exposure to UV-light.

[0361] The inflatable protective device may further comprise a valve for inflating and deflating, or respectively pressurizing and depressurizing connected inflatable chambers. That is, the protective device may comprise a valve providing a means to access the inflatable chambers in order to inflate / deflate the chambers. Preferably, at least some of the inflatable chambers of the chamber arrangement are fluidly interconnected such that all of the interconnected chambers can be pressurized / depressurized through the valve. In some embodiments, the protective device may further comprise a pressure relief valve, which may advantageously allow for preventing overpressure within the chamber and may also be advantageous in case of an impact as overpressure within the chambers due to the impact may be relieved, which may advantageously reduce a potential rebound. In some embodiments the pressure relief valve may be configured to switch between two pressure configurations, wherein a lower-pressure configuration may be utilized when inflating the protective device and a higher-pressure configuration may be utilized once inflated for the relieving overpressure in case of an impact. For example, the user may choose the lower- pressure configuration when pressurizing the protective device to avoid overpressure and then switch to the higher-pressure configuration while using the protective device for relieving overpressure in case of an impact. Alternatively, the pressure relief valve may be configured to identify whether the protective device is being inflated or subjected to an impact and apply the respective configuration. The pressure relief valve may be combined with the valve for inflation / deflation.

[0362] The composite material may comprise sufficient flexibility for the inflatable protective device to be folded in deflated (i.e., unpressurised) state. Thus, the composite material may be foldable.

[0363] The textile material and the fluid-tight, elastic material may be laminated to create a material bond, preferably hot laminated. That is, the layers may be pressed together and heated such that the fluid-tight layer melts and permanently sticks to the textile layer, in other words it may fuse with the textile layer. Preferably, thermally laminating the fluid- tight, elastic laxer and the textile layer may form the composite material. In some instances, glue / adhesion may additionally or alternatively be utilized to establish the permanent connection.

[0364] In some embodiments, a most proximal chamber layer of the chamber arrangement may not be fluidly connected to any other chamber layer of the protective device and may be configured to hold a low pressure of less than 0.5 bar, preferably less than 0.3 bar. That is, while it may be able to withstand higher pressures it is designed to only be pressurized up to 0.5, preferably 0.3 bar in order to provide means for adjusting to various shapes. In other words, said layer, which may also be referred to as adaptation layer may be pressurized to less than 0.5 bar, preferably less than 0.3 bar when in use. Such an adaptation layer may advantageously allow a comfortable fit to the shape of body part or object to be protected, and thus provide a snug fit and potentially increase wearing comfort for a user. In such a case, preferably all other chambers of the chamber arrangement are fluidly connected. In case without such an adaption layer for better fit, preferably all chambers of the chamber arrangement are fluidly connected.

[0365] Overall, the inflatable protective device may thus provide protection for a wearer's body part or an object through the inflatable chambers providing air cushions, wherein in case of an impact air within the chambers may compress and / or redistribute, and the overall shape of the chambers may deform non-destructively. This may have the advantage of an improved level of protection as the impact energy is not dissipated, e.g., by destroying the hard foam of a conventional helmet, but rather converted through elastic deformation and fluid compression. Therefore, the inflatable protective device may advantageously be reused after experiencing an impact as any damage would be easily accessible, e.g., a hole in the composite material would be directly apparent to a user. Furthermore, compression and redistribution of the air may advantageously prolong the duration of an impact compared to common protective devices, e.g., helmets, which reduces the maximum acceleration experienced and thus further increases the level or protection. Additionally, the inflatable protective device according of the present invention may utilize less material than common protective devices. In other words, a protective device according to the present invention may advantageously be more resource-efficient than conventional protective devices currently used.

[0366] The present invention further relates to a method for manufacturing an inflatable protective device. For example, with reference to Figs, la-lc, the method may generally comprise the steps of providing at least two different materials (step 100), preferably comprising a textile material and a fluid-tight, elastic material.

[0367] Furthermore, the method may generally comprise forming these materials (step 120) and joining these materials (step 140) to provide a respective composite material. Subsequently, the formed and joined materials (i.e., the formed composite material) may be cut and / or punched (step 160) to provide at least one external chamber section of formed composite material in a desired shape. For example, edges may be trimmed and or the formed and joined materials may be divided into a plurality of chamber sections.

[0368] Finally, a collection of at least one e chamber section may be welded together to provide a chamber arrangement of interconnected chambers (step 180), wherein the collection of at least one chamber section comprises at least one external chamber section. That is, at least one external chamber section may be welded together, however also a plurality of chamber sections particularly comprising at least one external chamber section as well as an internal chamber section may be welded together. It will be understood that an external chamber section is a chamber section that may constitute external chamber walls and particularly at least part of an external surface of the chamber arrangement. Preferably welding may comprise high-frequency welding.

[0369] It will be understood that particularly the order of the steps of forming and joining the materials (steps 120, 140) may be different for different embodiments of the present invention. That is, in some embodiments, the materials may first be formed (step 120) and then subsequently be joined (step 140) to provide the composite material, e.g., at the end of the forming step 120. However, in other embodiments the materials may first be joined to form the composite material (step 140) and only afterwards the materials may be formed (step 120). Put differently, in such a case the materials are formed by means of forming the composite material. That is, forming the materials may also refer to forming the composite material comprising these materials. In some cases, the materials may be formed and joined at least partially simultaneously. That is, the steps of forming and joining the materials (steps 120, 140) may at least partially be performed simultaneously, e.g., using a heated mold for forming the materials and simultaneously joining the materials to provide the composite material. Additionally or alternatively a heated active media may be provided for forming and / or joining. In particular, active media comprising at least one heated component may be prided. For example, the active media may be a combination of unheated air and heated steam.

[0370] Forming the materials may for example be done by thermoforming (sometimes also referred to as deep drawing), e.g., vacuum forming, or by forming based on active media, e.g., hydroforming using a hydraulic fluid or forming by means of pressurized air, gas and / or steam.

[0371] Joining the materials to provide a composite material may generally comprise providing a material bond between the respective materials. This may for example be chieved through adhering / gluing, and / or, preferably, through lamination, more preferably through heated lamination.

[0372] With respect to Figs. 2a-2c some steps of the method in accordance with an exemplary embodiment are discussed. As mentioned at least two different materials 1, 2 may be provided. These materials may preferably be provided as sheets of material, which may for example comprise a foil of a certain material. Preferably, a textile material 1 and a fluid-tight, elastic material 2 may be provided. The at least two different materials 1, 2 may subsequently be formed, preferably using a respective mold 10 or a forming die 10 comprising a surface resembling a desired shape for the materials. In the following reference is made to a mold for sake of simplicity, however, it will be understood that instead a forming die may be used unless explicitly stated otherwise. The materials (e.g., layers or respectively sheets of material) may then be layered and placed in or on the respective mold 10, e.g., thermoforming mold. Subsequently the layered materials are pressed or drawn into / onto the mold to be formed into the respective shape. For example, pressurized fluid(s), such as pressurized air, gas and / or steam 12 may be utilized to press the layered materials in the mold, or vacuum may be used to draw the layered material into the mold 10.

[0373] In some embodiments, the mold 10 may be heated when forming the materials 1, 2 while in other embodiments the mold 10 may be cold (i.e., not heated and thus typically at or around room temperature) during forming of the materials and only heated once the material is already lying against a surface of the mold, e.g., an inner surface of a negative mold. Heating of the mold 10 and thus particularly the materials may be advantageous for increasing the materials elasticity during forming and / or be part of joining the materials to provide a composite material. Further, heating and particularly joining the materials may additionally serve to ensure that the formed material maintains the desired shape. In particular, heating the materials may allow for heated lamination of the materials 1, 2 to provide the composite material. In other words, the step of joining the materials to provide a composite material may comprise heating of the materials, e.g., through the mold, to enable heated lamination.

[0374] In case of forming based on active media, the active media 12 (e.g., pressurized air) may be heated to facilitate the process. Generally, the active media may comprise 1 or more fluids, e.g., a combination of air and steam. It will be understood that in some instance only some of the constituents, preferably fluids, of the active media may be heated. For example, unheated air may be combined with heated steam to provide the heated active media. In some instances, it may be sufficient to only heat the active media, e.g., pressurized steam, to sufficiently heat the materials, such that advantageously no heating of the mold / forming die may be required.

[0375] Thus, forming and joining of the materials may be carried out at the same time (i.e., when the mold is already heated during forming of the materials), or the material may be joined once formed in the mold 10.

[0376] It will be understood that instead of forming loosely layered materials 1, 2 these materials may also first be joined to provide a composite material and then formed as described above. In such a case, the material may typically be heated during forming, e.g., through heating the mold 10 and / or the active media. Overall, the different embodiments described above in conjunction with Figs. 2a and 2b lead to formed and joined materials 4 being provided by means of forming utilizing a mold 10 and heating of the materials. The formed and joined materials 4 may also be referred to as formed composite material 4.

[0377] The formed and joined materials 4 may then be cut and / or punched to clean an outer rim and / or provide desired outer dimensions, thereby providing at least 1 external chamber section of formed composite material 6. Cutting and / or punching the formed and joined materials may for example be done using a die, which may in some cases be provided together with the forming die as a single die. Depending on the mold 10, it may also be possible that through cutting and / or punching the formed and joined materials more than 1 chamber section of formed composite material is provided.

[0378] Generally, the above steps may be repeated to provide a plurality of external chamber sections, i.e., at least two external chamber sections. It will be understood that the respective mold or forming die used for forming and / or joining the materials may be different for different external chamber sections. That is, in case of a plurality of external chamber sections the respective chamber sections may differ in shape. Subsequently, a collection of at least one chamber section, comprising at least one external chamber section of formed composite material may be welded together to create a chamber arrangement of interconnected chambers. For example, a single external chamber section may be folded and welded to provide the chamber arrangement. Similarly, two external chamber sections may be welded together to form a chamber arrangement, e.g., a chamber arrangement as depicted in Fig. 3a. In some instances, the at least one external chamber section may be combined and welded together with at least one internal chamber section to provide the chamber arrangement, e.g., a chamber arrangement as depicted in Fig. 3b. In another arrangement depicted in Fig. 3c one external chamber section has inner walls and another chamber called additional chamber which is fluidly connected to the external chamber and fixed to it in a distal direction to provide the chamber arrangement.

[0379] The welding may preferably be high-frequency welding, e.g., using respective welding electrodes 14. This may advantageously allow to provide a layer of interconnected chambers in a nearly arbitrary design. High-frequency welding may either be realized by exerting pressure in a single direction (2-dimensional welding), consequently leading to all welding joints being oriented in the same direction (orthogonal to the direction in which pressure is applied), or preferably by using a 3-dimensional welding process such that welding joints may be orthogonal to the proximal-to-distal direction.

[0380] In addition, the method may comprise welding in a valve to enable inflating and deflating of the interconnected chambers. This step may typically be performed prior to welding together the at least one chamber section. Thus, the valve may be welded into one of the at least one chamber section, particularly an external chamber section and preferably an external chamber section which is configured to provide at least part of the outside or respectively distal portion of the chamber arrangement, wherein the outside (or respectively distal portion) denotes a portion of the chamber arrangement that is further away from a head of the wearer when worn compared to the inside of the chamber arrangement, which may typically be configured to receive the head of a wearer. In other words, the chamber arrangement may comprise an outside and an inside, wherein the outside is further away from the object or body part to be protected, e.g., a wearer's head, than the inside when in use. That is, the outside is more distal to the object or body part when in use compared to the inside, which is thus more proximal to the object or body part to be protected when in use.

[0381] Furthermore, the method may comprise attaching fixation means to the chamber arrangement, preferably to a proximal portion or respectively inside of the chamber arrangement. The fixation means may be configured for fixing the protective device to a body part or object to be protected, e.g., fixing the helmet to the head of a wearer when in use. Preferably such fixation means may comprise at least one webbing strap.

[0382] The method may further comprise designing the protective device. Preferably, designing the protective device comprises using a computer-aided design (CAD) Software. In other words, designing may preferably comprise providing a digital model of the protective device. Designing the protective device may further comprise simulating a geometry of the protective device. In particular inflation of the chambers may be simulated to determine how the chambers behave and / or alter their shape under pressurization.

[0383] Furthermore, the method may comprise providing at least one respective mold or forming die, preferably a respective negative mold, based on the designed protective device, preferably the digital model of the protective device. Preferably the mold or forming die may be made of metal, e.g., aluminium or preferably steel.

[0384] Generally, an inflatable protective device according to the present invention may provide some flexibility regarding the shape of the inflatable chambers and / or the protective device.

[0385] In the following reference will be made to a helmet and / or a chamber arrangement for a helmet as suitable an example for a protective device. However, it will be understood that the described features are not exclusive to a helmet but may also be realized in other protective devices according to the present invention unless otherwise stated. Examples for further protective devices may be protectors such as knee protectors, elbow protectors, or hip protectors which may also be referred to as knee pads, elbow pads, and hip pads, as well as wrist protectors, which may also be referred to as wrist guards, and spine protectors. These may for example be used for sports, during work as PPE or also when using certain means for transport, e.g., a motorcycle.

[0386] With reference to Fig. 3a, a helmet may comprise a plurality of inflatable chambers 20, which are fluidly connected and may thus be referred to as interconnected inflatable chambers 20. The plurality of inflatable chambers is comprised in a chamber arrangement 18. Generally, these chambers 20 may be defined by respective chamber walls 22, 28, wherein at least external chamber walls 22 of the chamber arrangement 18 comprise a composite material 4, and preferably are made of and thus constituted by the composite material 4. It will be understood that the term "external chamber walls" refers to those chamber walls 22 of the chamber arrangement that constitute an external surface of the chamber arrangement 18.

[0387] The chambers 20 being fluidly connected or respectively interconnected refers to there being means for a fluid to travel between adjacent chambers. This can for example be achieved by providing respective channels 23 and / or holes 24 connecting the chambers 20. With reference to Fig. 3a, the depicted cross section exemplarily illustrates such channels 23 between the two chambers 20 on the right-hand side and the left-hand side, respectively. Such channels may for example be realized through small tubes or respectively shaped materials. It will be understood that such channels 23 and / or holes 24 may not necessarily lie in the same cross-sectional plane but may be located in different cross-sectional planes. For example, arrangement may take into consideration or even be optimized with respect to air movement and / or energy dissipation in case of an impact.

[0388] The composite material 4 generally comprises a textile material 1 and a fluid-tight elastic material 2 that are permanently connected to each other. Furthermore, the composite material 4 is arranged such that the fluid-tight, elastic material provides an inner surface 22b of the respective external chamber wall 22. The textile material 1 may preferably constitute an outer surface 22a of the respective external chamber wall 22 and thus at least part, preferably all of the chamber arrangement 18.

[0389] Generally, the chamber arrangement 18 may comprise at least one chamber layer LI. That is, the chamber arrangement 18 may comprise at least one layer comprising a at least one inflatable chamber 20, preferably a plurality of inflatable chambers 20. The chambers of a layer are preferably interconnected. For example, the exemplary embodiment depicted in Fig. 3a comprises a single chamber layer LI comprising a plurality of interconnected chambers 20 (not all fluidic connections shown). A chamber arrangement 18 only comprising a single chamber layer LI, may thus not comprise chambers 20 overlapping in a direction from the inside to the outside (i.e., in the proximal-to-distal direction) of the chamber arrangement 18 and respectively the helmet. Preferably, when comprising only a single chamber layer, all chamber walls may be external chamber walls.

[0390] The chamber arrangement may be formed of a collection of at least one chamber section comprising at least one external chamber section that may be welded together to provide the chamber arrangement. Thus, the chamber arrangement may comprise welding joints 26, which may preferably be located between adjacent chambers of the same chamber layer.

[0391] In contrast, with reference to Fig. 3b a chamber arrangement comprising two chamber layers LI, L2 may comprise at least one chamber in one chamber layer LI that at least partially overlaps with a chamber of another, preferably adjacent chamber layer L2 in the proximal-to-distal direction. In fact, in the embodiment depicted in Fig. 3b each chamber 20 of the outer (distal) chamber layer L2 overlaps at least partially with at least one chamber of the inner (proximal) chamber layer LI. However, it is noted that also different designs may be possible. Preferably there may be at least one fluid connection 23, 24 between adjacent chamber layers, allowing to inflate and / or deflate the chambers 20 of a plurality of chamber layers through a single valve 37 fluidly connected to a chamber in one of the chamber layers, preferably a chamber of the outer (distal) chamber layer L2. That is, provided all chambers of a chamber layer are fluidly connected, which is preferred.

[0392] For example, adjacent chambers of neighbouring chamber layers may be fluidly connected by means of a hole 24 as illustrated in Fig. 3b. While all holes 24 are illustrated to lie in a single cross-sectional plane, it will be understood that this is for illustrative purposes only and that respective fluidic connections may lie in different cross-sectional planes. Generally, arrangement of fluidic connections (e.g., holes 24 and channels 23) may for example be chosen to optimize air flow with respect to energy dissipation, e.g., through turbulences. It may for example be desired to provide for an increased distance between fluidic connections of a chamber to extend the paths along which air needs to be moved in case of an impact.

[0393] However, in some embodiments, the chamber arrangement may comprise a chamber layer not fluidly connected to the other chamber layers of the chamber arrangement. Said disconnected chamber layer may be the proximal most chamber layer of the chamber arrangement. It may be configured to hold a low pressure of less than 0.5 bar, preferably less than 0.3 bar. That is, while it may be able to withstand higher pressures it is designed to only be pressurized up to 0.5, preferably 0.3 bar in order to provide means for adjusting to various shapes. In other words, said layer, which may also be referred to as adaptation layer may be pressurized to less than 0.5 bar, preferably less than 0.3 bar when in use. Such an adaptation layer may advantageously allow a comfortable fit to the shape of body part or object to be protected, and thus provide a snug fit and potentially increase wearing comfort for a user. All but that chamber layer may be interconnected.

[0394] With reference to Fig. 3b, in cases where the chamber arrangement 18 comprises a plurality of chamber layers LI, L2, internal walls of adjacent chambers of neighbouring layers LI, L2 may be provided through a shared internal chamber section 28. Further, it may be defined by respective chamber walls 22, 28. It will be understood that the term "internal walls" refers to chamber walls that are located within the chamber arrangement 18. In other words, the internal chamber section 28 may provide at least the internal walls. However, in some embodiments it may further also provide a portion of the external chamber wall(s). In such a case, it will comprise a composite material, which may be referred to as internal composite material. An internal chamber section 28 of the chamber arrangement 18 may comprise a fluid-tight, elastic material, preferably the same fluid- tight elastic material comprised by the composite material 4 of the external chamber walls 22. Thus, an inner surface of the external and internal chamber walls may be provided by fluid-tight, elastic material. In some embodiments the internal chamber section 28 of the chamber arrangement 18 may also comprise a composite material, which may also comprise a textile material and fluid-tight elastic material, wherein the textile material 1 may be sandwiched between fluid-tight elastic material 2. In other words, a layer of textile material may be located in between two layers of fluid-tight elastic material, one on each side of the layer of textile material. Preferably, the textile material of the internal chamber section may be the same as comprised by the composite material 4 of the external chamber walls 22. Thus, while basically comprising the same materials, the internal composite material of the internal walls may comprise a different composition.

[0395] The internal chamber section may be formed similar to the external chamber section. This may advantageously enable precise joining of the different chamber sections through welding.

[0396] Again, the chamber arrangement 18 may be formed of a collection of at least one chamber section comprising at least one external chamber section that may be welded together to provide the chamber arrangement. In the depicted embodiment, the collection of at least one chamber section further comprises an internal chamber section 28. That is internal and external chamber sections may be welded together, forming respective welding joints. Thus, the chamber arrangement 18 may comprise welding joints 26, which may preferably be located between adjacent chambers of the same chamber layer. It is noted that even at such welding joints 26, the internal chamber section is internal to the chamber arrangement since it is covered by a portion of the respective external chamber section it is welded to.

[0397] In contrast, with reference to Fig. 3c a chamber arrangement can comprise a single chamber layer LI, in which in contrast to the chamber arrangement disclosed in Fig. 3a, the two outer walls 22 are connected by at least one inner wall 129. The inner walls 129 can comprise several individual walls made of a laminated material 4. These inner walls can have the advantage that they prevent the two outer walls 22 from coming apart like a "balloon" when inflated. The inner walls 129 can be connected to the outer walls 22 at the weld points 26. The inner walls 129 are integrated into the air chambers 20 in such a way that the airtight plastic side 2 of the inner walls 129 is directed towards the outer wall 22 and welded to the airtight plastic side 2 of the composite material 4 of the outer wall 22 with the weld joint 26.

[0398] In principle, the chambers 20 may take any shape or form. Preferably, the shape and arrangement of chambers 20 may take into consideration security aspects, e.g. with regard particular protection of areas that may be at a higher risk of impact in cases of a fall. Chambers within a chamber layer may be defined through respective welding joints, which may provide flow restrictions between larger internal volumes of a chamber layer and thus define interconnected chambers. With reference to Figs. 4a to 4e an exemplary embodiment of a single layer of interconnected, inflatable chambers is shown, preferably such a chamber arrangement may be utilized for a helmet. Fig. 4a illustrates a first perspective view, Fig. 4b illustrates a side view, Fig. 4c illustrates a back view, Fig. 4d illustrates a front view, Fig. 4e illustrates another perspective view and Fig. 4f illustrates a top view. Generally, the chambers 20 may for example comprise a tube-like shape with an elliptical and / or round cross section. Such tube-like shaped chambers may be arranged to provide a respective chamber layer. For example, they may be partially and / or fully wound around a cavity designed to partially receive the head of a wearer.

[0399] For example, the layer of chambers may comprise at least one self-contained chamber 20a, 20b. That is, a chamber that does not comprise a closed end in its longer extension. For example, ring-like chamber 20a, i.e., a chamber that generally comprises a toroidal shape or torus-like shape. That is, it may not necessarily resemble a torus, but can also be an elliptical torus, wherein tube and / or cross section may be elliptical and or comprise slight bends along the tube.

[0400] Another example of a self-contained chamber 20a, 20b may be a three-part chamber 20b comprising three sections of tube-like chambers that are joined at their respective ends by means of a Y-piece, wherein each section approximately resembles a semi-circle or a half ellipse.

[0401] Furthermore, the layer of chambers may comprise at least one chamber resembling the shape of a section of a ring or a section of an elliptical torus. That is, a tube-like chamber with closed ends that is bend in shape of a section of a circle or a section of an ellipse.

[0402] In some embodiments, the chambers may comprise a discontinuous cross-section. In particular, a more proximal portion of the chamber may comprise a different cross-section than a more distal portion. With reference to Fig. 4a to 4e, while in the more distal portion chambers may comprise shapes as described above, the more proximal portion that is not visible in detail in the illustration may for example comprise a hexagonal cross section.

[0403] Preferably, the layer of interconnected chambers may be manufactured by welding together at most two external chamber sections of formed composite material, optionally in combination with an internal chamber section. In other words, the chamber arrangement may comprise at most two external chamber sections of formed composite material (and optionally an internal chamber section) that are welded together. This may render manufacture of the chamber arrangement less complex.

[0404] The welding joints 26 may preferably be located between adjacent chambers of a chamber layer and at an outer rim of the chamber arrangement. In other words, the welding joints of a chamber layer may preferably be located within a convex surface running through the chamber arrangement. This may be advantageous compared to having the welding joints at distal and proximal ends of the chambers as the total number of welding joints can be reduced and welding joints at the distal ends of chambers may disadvantageously more likely be subject to physical stress.

[0405] The chambers may be fluidly connected through respective channels 23 between adjacent chambers. In particular, each chamber may be fluidly connected to at least one adjacent chamber through a channel 23. Furthermore, all chambers may be fluidly connected to each other, e.g., via other chambers. For the depicted embodiment the textile material may preferably be a knitted fabric, particularly a weft knitted fabric.

[0406] Figs. 5a to 5e illustrate another exemplary embodiment of a chamber arrangement, preferably for a helmet. This chamber arrangement comprises two interconnected chamber layers. Fig. 5a illustrates a side view, Fig. 5b illustrates a back view, Fig. 5c illustrates a front view, Fig. 5d illustrates a perspective view and Fig. 5e illustrates a top view. Generally, the depicted chamber embodiment may comprise chambers similarly shaped to the embodiment depicted in Figs. 4a to 4f. Additionally, an inlet valve 36 and an outlet valve 38 are welded to the chamber arrangement. The inlet valve 36 may be configured for inflating / pressurizing the chamber arrangement, while the outlet valve 38 may be configured for deflating / depressurizing the chamber arrangement. Alternatively, a single valve 37 may provide for inflation and deflation of the chamber arrangement.

[0407] With respect to Figs. 6a to 6b another exemplary embodiment of a helmet comprising a chamber arrangement according to the present invention is discussed. The chamber arrangement 18 comprises two chamber layers LI, L2 that share an internal chamber section 28. In Figs. 6a to 6b mainly the first chamber layer LI can be seen.

[0408] Generally, the chamber arrangement 18 of the helmet depicted in Figs. 6a to 6b is made of a collection of 3 chamber sections: 2 external chamber sections 30 and 1 internal chamber section 28, wherein the internal chamber section constitutes internal chamber walls. Additionally, in the depicted design, the internal chamber section 28 may also provide a portion of the external chamber walls due to difference in shape of the two chamber layers LI, L2.

[0409] The two chamber layers may also be interconnected. However, fluid flow between neighbouring chamber layers may be restricted, e.g., by only providing very limited fluidic connections, e.g., a single hole in the internal chamber section 28.

[0410] The internal chamber section may comprise an internal composite material, which may comprise the textile material sandwiched between the fluid-tight, elastic material.

[0411] Again, a valve 37 may be welded to the chamber arrangement for allowing inflation / deflation of the chamber arrangement.

[0412] For example, Fig. 7a depicts the chamber sections of the chamber arrangement 18 depicted in Figs. 6a to 6b. In particular, it illustrates the two external chamber sections 30, 30-1, 30-2 and the internal chamber section 28, wherein 30-1 denotes the distal external chamber section and 30-2 denotes the proximal external chamber section. It can be seen that the internal chamber section 28 only comprises a single hole for allowing a fluid connection between the two chamber layers. Thus, the external chamber section 30-1 may be welded to the internal chamber section 28 to provide the first chamber layer LI and the second external chamber section 30-2 may be welded to the internal chamber section 28 to provide the second chamber layer L2, which is more proximal than the first chamber layer LI. To bring the chamber arrangement in a bended form all the fingers 34 will be fixed together at the end of the fingers 134.

[0413] With respect to Figs. 8a to 8d another exemplary embodiment of a helmet comprising a chamber arrangement according to the present invention is discussed. The device can comprise of two regions 101 and 102 separated by the two bended axis A2. The axis Al is the symmetry axis of the device. The central region 101, which can protect the front, the upper region and the rear region of the head, can have a chamber arrangement with inner walls 129 and outer walls 22 which are connected to each other at the welding lines 26. in region 102 the fingers 34 extend from region 101 in the lateral area of the device. With reference to Fig. 3c, these fingers can also consist of a chamber arrangement with outer walls 22 and inner walls 129 and in which the walls are connected to each other at the welding points 26.

[0414] The connections of the finger 34 with the chamber arrangement in the region 101 is illustrated in Figs. 8c and d. The fingers 34 are sewn together with an interlocking or stitching 113 so that they form a double-curved shape. To achieve this, the outer weld seams 126 at the end of the fingers 134 or on the sides of the fingers 134-1 are interlocked or sewn together.

[0415] Fig. 8e shows an embodiment of the device in which the fingers 34 are joined together with several rivets 112 so that they form a double-curved shape. For this purpose, holes

[0416] 111 are made in the outer weld seams 126 at the end of the fingers 134 or on the sides of the fingers 134-1. The holes 111 are used to connect the fingers 34 together with rivets

[0417] 112 to give the chamber arrangements a double-curved shape

[0418] With reference to Fig. 8a, the foremost fingers 134-2 are longer than the trailing fingers 134-3. The trailing fingers 134-3 are connected by their ends 134 to the sides 134-1 of the foremost fingers 134-2. With reference to Fig. 8c, this connection can be realized with an interlock or stitching 113. Alternatively, with reference to Fig. 8d, this connection can be realized with rivets 112.

[0419] A combined version of the inlet valve 36 and the outlet valve 38 may be welded in one unit to the chamber arrangement for allowing inflation / deflation of the chamber arrangement. The inlet and outlet version of the valve a combined in a single valve for fast inflation / deflation and comprises a pressure indicator. With reference to Fig. 9a to 9e the chamber arrangement comprising outer chambers 20 and the additional chamber 120 show different ways of fixing the channels of the additional chamber 120 to the outer chambers 20 and the additional chamber 120 themselves to the outer chambers 20. The arrangement of the additional chambers 120 are at least fluidly connected on one point through at least one hole in a welding joint 124 in Fig. 9b and / or a channel 23 (see Fig. 10, 23). This chamber arrangement can be seen as multiple layers.

[0420] Demonstrated in Fig. 9a the channel 23 is the connection between the additional chamber 120 so that they are fluidly connected to each other. These channels can be attached in two ways to the outside chambers in a distal direction. In the first case they can be attached through the holes for rivets 111 with rivets 112 and in the second case they can be additionally attached through the interlocking seam 113 on the outside of the contour welding 126.

[0421] With reference to Fig. 9c one way is welding the additional chambers 120 with a welded inner layer 130 which serves as a welding point and is welded to the points, which have weldable cutouts in the layer 130-1, of the outer chambers 20 between two fingers 34 where no air cushion exists but only composite material 4. Here the additional chambers 120 are only attached constantly and have no fluid connection. To add, another welded inner layer 130 is welded onto the outer wall on the opposite of the attachment point for protecting it during the welding process and when inflated. The same method applies to 9b but with the difference that the welding joint 124 has a fluid connection and the counterpart it will be welded onto is a chamber 20. The other way to connect the additional chambers 120 can be to have a masculine attachment clip 114-1 (Fig. 9e) welded in in a hole in the additional chamber 120 so that it is air tight and can be clipped into the feminine counterpart clip 114-2 (Fig. 9d and 9e) which is welded into the welding joints 26 of the external chamber section 30 so that they hold together substantially permanently. They have no fluid connection on this exact attachment point.

[0422] Figs. 10 shows a section of a 2-dimensional chamber layer pattern. A base principle of the pattern is similar to referral 30, 30-2 in Fig. 7a but references to the new chamber arrangement of Fig. 8 where the main difference is the usage of inner walls 129 and additional chamber 120. The pattern comprises the additional chambers 120, the fluid connection channel 23 of them to at least one of the fingers 34 and a plurality of parallel fingers 34 that can be mirror-symmetrically arranged to an axis Al perpendicular to the fingers. When assembled, said axis may follow a curvature of the helmet while running in a direction from front to back of the helmet. Consequently, the mirror-symmetrically arranged fingers 34 will be on either side of the device. Furthermore, the fingers 34 will overlap at least partially and joined together at least one point 111 with a rivet 112 or connected with an interlocking seam 113 at each side of the helmet, thereby creating the curvature of the helmet.

[0423] If the attachment method is welding each additional chamber 120 can have a hole where the welded inner layer 130 will be welded onto so that the fluid tight elastic material 2 points to the external chamber wall 22 and serves as a welding spot. The fingers 34 have round weldable cutouts in the layer 130-1 because the 8 fluid tied elastic material 2 of the other layer shows through when welded together. This welding spot is the counterpart to weld it together with the welded inner layer 130 so the additional chambers 120 can be attached via welding.

[0424] Whenever a relative term, such as "about", "substantially" or "approximately" is used in this specification, such a term should also be construed to also include the exact term. That is, e.g., "substantially straight" should be construed to also include "(exactly) straight".

[0425] Whenever steps were recited in the above or also in the appended claims, it should be noted that the order in which the steps are recited in this text may be accidental. That is, unless otherwise specified or unless clear to the skilled person, the order in which steps are recited may be accidental. That is, when the present document states, e.g., that a method comprises steps (A) and (B), this does not necessarily mean that step (A) precedes step (B), but it is also possible that step (A) is performed (at least partly) simultaneously with step (B) or that step (B) precedes step (A). Furthermore, when a step (X) is said to precede another step (Z), this does not imply that there is no step between steps (X) and (Z). That is, step (X) preceding step (Z) encompasses the situation that step (X) is performed directly before step (Z), but also the situation that (X) is performed before one or more steps (Yl), ..., followed by step (Z). Corresponding considerations apply when terms like "after" or "before" are used.

[0426] While in the above, a preferred embodiment has been described with reference to the accompanying drawings, the skilled person will understand that this embodiment was provided for illustrative purpose only and should by no means be construed to limit the scope of the present invention, which is defined by the claims.

Claims

Claims1. An inflatable protective device comprising a chamber arrangement comprising a plurality of inflatable chambers, wherein the chambers are defined by chamber walls, and wherein at least external chamber walls of the chamber arrangement comprise a composite material, wherein the composite material comprises a textile material and a fluid-tight, elastic material that are permanently connected to each other, and wherein the composite material is arranged such that the fluid-tight, elastic material provides an inner surface of the respective external chamber walls.

2. The device according to the preceding claim, wherein at least one air chamber, in an inflated state, are forced into a preferred shape of the device by forcing the air chambers together by defining connections.

3. The device according to any one of the preceding claims wherein joining of all fingers on the left and right sides allows additional forcing of the air cushions into the desired shape, regardless of the method of joining.

4. The device according to any one of the preceding claims wherein welded walls within an air chamber prevent ball-like inflation of the chamber arrangement to hold the outer walls of the chamber arrangement in form.

5. The device according to any one of the preceding claims wherein the welded inner walls create areas that bend more easily and are conducive to the overall shape by varying the height of these walls.

6. The device according to any one of the preceding claims, wherein the device comprises at least two regions (101, 102) from which one covers at least one of the front region, the upper region and the rear region of a head and another one can cover the at least one lateral region of the head.

7. The device according to any one of the preceding claims wherein a chamber arrangement comprising of at least two outer walls (22) connected to at least one inner walls (129) by welding lines (26) protects the central region (101) covering at least one of the front, the upper region and the rear region of the head.

8. The device according to any one of the preceding claims, wherein the distal chamber layer comprises a plurality of parallel fingers that are mirror-symmetrically arranged to an axis perpendicular to the fingers, wherein the fingers on either side of the axis may each respectively be joined in at least one point, thereby creating a curvature of the chamber assembly.

9. The device according to any one of the claims wherein the method of joining the fingers is interlocking.

10. The device according to any one of the preceding claims wherein the fingers comprise a chamber arrangement (LI) comprising at least two outer wall (22) and / or comprises at least one inner wall (129) wherein the walls are connected to each other at the welding lines (26).

11. The device according to any one of the preceding claims, wherein the plurality of inflatable chambers comprises at least one finger that are joined together with another finger in such a way that the device takes on a double-curved shape and becomes semi-circular or helmet-shaped.

12. The device according to any one of the preceding claims, wherein the upper 2 fingers and the lower 2-4 fingers are joined under the apex of a hemisphere, creating a ring that can absorb all stresses of the fingers without forming a flat cushion thus defining the final shape of the device.

13. The device according to any one of the preceding claims, wherein the fingers are joined in such a way, that they bend in lateral direction to support the semi hemispherical form.

14. The device according to any one of the claims wherein the method of joining the fingers is interlocking.

15. The device according to the preceding claim, wherein additional chambers are fitted inside the helmet configured to cover weak points, such as welding points or areas between two chambers which are not provided with any other chamber.

16. The device according to any one of the preceding claims wherein the additional chambers are connected with the device through at least one hole or channel made of the same material as the device and are physically connected at at least one point.

17. The device according to the preceding claim wherein the additional chambers are connected with the device through welding.

18. A method for manufacturing an inflatable protective device comprising a chamber arrangement of inflatable chambers, the method comprising providing at least two different materials; forming the materials; joining the materials to provide a composite material; cutting and / or punching the formed and joined materials to provide at least one external chamber section of formed composite material;welding together a collection of at least one chamber section, comprising at least one external chamber section of formed composite material to provide the chamber arrangement.

19. The method according to claim 18, wherein forming the materials comprises forming the materials using a respective mold or forming die.

20. The method according to any one of the claims 18 or 19, wherein the at least two materials are layered and subsequently pressed or drawn into or onto the mold or forming die.

21. The method according to any one of the claims 18 to 20, wherein at least one of the materials is pre-shaped to roughly approximate a desired overall shape.

22. The method according to any one of the claims 18 to 21, wherein joining the materials comprises heating the mold or forming die.

23. The method according to any one of the claims 18 to 22, wherein the mold or forming die is heated prior to forming of the materials.

24. The method according to any one of the claims 18 to 23, wherein the mold or forming die is heated after forming of the materials.

25. The method according to any one of the claims 18 to 24, wherein forming the materials comprises forming by thermoforming or by forming based on active media.

26. The method according to any one of the claims 18 to 25, wherein the active media comprises pressurized fluid.

27. The method according to any one of the claims 18 to 26, wherein the active media comprises pressurized air, gas and / or steam.

28. The method according to any one of the claims 18 to 27, wherein the method comprises providing heated active media for joining the materials.

29. The method according to any one of the claims 18 to 28, wherein the method comprises providing heated active media for forming the materials.

30. The method according to any one of the claims 18 to 29, wherein the chamber arrangement comprises a plurality of chamber layers.

31. The method according to any one of the claims 18 to 30, wherein the plurality of chamber layers are arranged such that each chamber layer comprises at least one chamber that at least partially overlaps with a chamber of an adjacent layer in the proximal-to-distal direction.

32. The method according to any one of the claims 18 to 31, wherein adjacent chamber layers are arranged such that weld joints located within a chamber layer do not overlap with weld joints within an adjacent chamber layer in the proximal-to-distal direction.

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