Protective helmet with a reversible lockable recess for cable feedthrough

Abstract

The invention relates to a protective helmet (1), a method for manufacturing such a protective helmet (1), a method for equipping such a protective helmet (1) with a communication system, and finally a system comprising a protective helmet (1) and a communication system. According to the proposal, a recess (18) is provided for the passage of a cable (12) of a communication system, which is reversibly closable with a molded part (17).

Description

[0001] The present invention relates to a protective helmet, such as those intended for motorcyclists. The invention further relates to a method for manufacturing a protective helmet, a method for equipping a protective helmet with a communication system, and a system comprising a protective helmet and a communication system.

[0002] In the field of protective helmets, particularly motorcycle helmets, it is of paramount importance that the structural components remain intact throughout the helmet's use, thus ensuring continuous protection against impact forces for the wearer. In known systems, this is achieved primarily through an outer shell that distributes the impact forces and an inner layer that dampens these forces.

[0003] Modern protective helmets are also often equipped with additional features, such as integrated communication systems that allow the wearer to communicate or receive instructions while riding.

[0004] Currently, communication systems in safety helmets are either integrated at the factory, providing a complete system consisting of a helmet and a communication system. This often involves permanently installed cables and speakers, for example, those bonded or glued to the helmet. These systems often require complex installation during manufacturing and can compromise the helmet's structural integrity if subsequent modifications are necessary. The connection points, particularly adhesive joints, can be damaged when the communication system or its components are replaced, potentially harming structural components where these connection points are often located. This can compromise the safety of the safety helmet.

[0005] Furthermore, there are safety helmets that are not equipped with a communication system from the factory. In these cases, helmet wearers often retrofit their helmets with communication systems themselves, which also involves routing the necessary cables. This regularly results in openings, cutouts, and similar modifications to the helmet, such as cutting or perforating the inner layers or, alternatively, the helmet's edge profiles. This process damages structural components of the helmet that are designed to distribute and absorb impact forces or otherwise protect the structural components from mechanical damage. This compromises the helmet's safety.

[0006] If the helmet wearer does not take any such damaging measures to route the cable to the helmet, the cable will usually be routed in a way that is disruptive to the wearer or interferes with the interaction of the helmet's components (such as the inner padding and the inner lining). It is detrimental, and also to the operational reliability of the communication system itself, if the cable lies loosely on the inside of the inner lining or even extends into the padding or the helmet's interior. Furthermore, arranging to glue or otherwise fix the cable to any existing structural components of the helmet is undesirable in order to maintain the integrity of these components.

[0007] It is therefore an objective of the present invention to provide a protective helmet or a system comprising a protective helmet and a communication system that overcomes at least one of the aforementioned disadvantages of known systems, at least partially. In particular, simple and non-destructive integration and removal of communication systems should be possible. Specifically, there is a need for protective helmets that allow communication system cables to be routed and removed easily and without compromising the helmet's structural integrity. Furthermore, such solutions should ensure that the helmet's protective function is not impaired and that the installation and maintenance of the communication systems are user-friendly and efficient. Corresponding manufacturing methods for the protective helmet or...The system, which includes a protective helmet and a communication system, should be able to run as efficiently as possible with as few production steps as possible.

[0008] This problem is solved for a protective helmet with the features of the preamble of claim 1 by the features of the characterizing part of claim 1. Furthermore, this problem is solved for a method for manufacturing a protective helmet with the features of the preamble of claim 11 by the features of the characterizing part of claim 11. This problem is also solved for a method for equipping a protective helmet with a communication system by a method with the features of claim 12. Finally, this problem is solved for a system comprising a protective helmet and a communication system by a system with the features of claim 14. Advantageous embodiments of the protective helmet, the methods, and the system are the subject of the dependent claims and the following description.

[0009] The key finding here is that a universal protective helmet can be provided, allowing the wearer to easily and independently add or replace various compatible communication systems or components as needed. Crucially, thanks to the factory-installed recess for a communication system cable, complete with a molded part that seals this recess and reveals it upon removal, the wearer no longer needs to perform any damage to the helmet to route the cable safely and discreetly. All steps can be carried out manually by the wearer, including, if necessary, adjusting the molded part itself, although tools or aids may be used for this purpose.The helmet itself, primarily through the recess, but also potentially through other elements such as a cable channel and a recess for a speaker, already provides the necessary means to safely route and conceal a communication system cable within the helmet. The reversible closure of the recess with the molded part allows for both easy retrofitting of the helmet with a communication system and simple maintenance and adjustment of communication systems already integrated into the helmet.

[0010] The proposed protective helmet, which is specifically a motorcycle helmet, has an outer shell to distribute impact forces. The proposed protective helmet also has an inner layer to dampen impact forces, which is sometimes also called the inner shell.

[0011] The protective helmet, which is preferably a motorcycle helmet, could alternatively be a military helmet, a combat helmet, a police helmet, or a pilot's helmet. It could also be a firefighter's helmet, a forestry helmet, or a work helmet.

[0012] The material of the outer shell can vary depending on the application. The outer shell, sometimes also called the helmet shell, should be highly stable and hard. The outer shell can be made of fiber-reinforced thermoset plastic or consist primarily of fiber-reinforced thermoset plastic, or of thermoplastic material or consist primarily of thermoplastic material (which allows for injection molding of the outer shell), or of metal or steel or consist primarily of metal or steel. Paint or stickers may also be applied to the outside of the outer shell; the material of these is not considered part of the outer shell material in this context. Examples of thermoplastic materials are polycarbonate (PC) and acrylonitrile butadiene styrene (ABS).Alternatively, glass fiber reinforced plastic (GFRP), carbon fiber reinforced plastic (CFRP) or polyamide (PA) can also be used.

[0013] The material of the inner layer can also vary. The inner layer, also called the inner shell, helmet inner shell, or impact-absorbing dome, is designed to provide good shock absorption and is typically softer than the outer shell. The inner layer can, in particular, comprise a plastic foam, preferably a plastically deformable foam, more preferably particle foam, and more preferably EPS, EPP, or PUR, or consist essentially of a plastic foam, preferably a plastically deformable foam, and more preferably particle foam, and more preferably EPS, EPP, or PUR. Examples of plastic foams are expanded polystyrene (EPS), expanded polypropylene (EPP), and expanded polyethylene (EPE). The inner layer is preferably manufactured using a foaming process in which the inner layer is directly foamed onto the inside of the outer shell.

[0014] The outer shell has an outer surface facing the external environment and, opposite the outer surface, an inner surface facing the helmet interior. The inner layer is located inside the inner surface of the outer shell. The inner layer is bonded to the inner surface of the outer shell, preferably by means of a foaming process.

[0015] The proposed safety helmet has a recess designed for the routing of a communication system cable. This recess can be reversibly closed by a molded part. The molded part can be manually removed and reinserted, allowing the communication system cable to be connected to or disconnected from the helmet without damaging its structural components. The recess is thus designed to be reversibly closed by the molded part, or, when closed, is closed in such a way that, by manually removing and reinserting the molded part, the communication system cable can be connected to or disconnected from the helmet without damaging its structural components.After the molded part is reinserted, the recess remains closed, meaning that the closed state of the recess is essentially maintained.

[0016] One advantage of this design is the ability to easily and non-destructively integrate or remove a communication system from the helmet, simplifying helmet fitting and maintenance. Another advantage is the protection against wind, dirt, and moisture, which is particularly important for motorcycle helmets. The molded part ensures a sufficient seal at all times, whether the communication system is completely absent or installed with the cable routed through the opening, thus preventing any potential negative acoustic effects from such an opening.

[0017] The recess is designed to be reversibly closed with the molded part, allowing the molded part to be removed and reinserted without damaging any structural components of the helmet. This contributes to the helmet's durability and safety, as no permanent alterations or damage are required to the helmet's inner lining, outer shell, or even its edge. Furthermore, the reversible closure of the recess allows for flexible helmet use, as the wearer can easily install or remove the communication system as needed. This is particularly advantageous for users who wish to use the helmet in various contexts, with or without a communication system.

[0018] Preferably, the molded part is positively inserted into the recess when the recess is closed by the molded part. In particular, a partial press fit can also be provided, especially by slight deformation of the molded part, whereby restoring forces can support the seating of the molded part in the recess. Preferably, the molded part is elastic and flexible.

[0019] The molded part may also have predefined weakenings or perforations to facilitate manual partial adjustment of the molded part for cable routing.

[0020] According to a preferred embodiment of the protective helmet, the opening for routing a communication system cable is located on the underside of the helmet. The underside of the helmet is the side through which the wearer's head can be inserted into the helmet's interior via a corresponding head-entry opening. Positioning the opening at this location offers the advantage of discreet and protected cable routing, as the underside of the helmet is generally less exposed than other areas. This reduces the risk of cable damage from external influences such as wind, dirt, or moisture. The opening can be located, in particular, on a side of the underside of the helmet surrounding the head-entry opening.

[0021] According to a preferred embodiment of the protective helmet, an underside edge profile has a recess for routing a communication system cable. This underside edge profile is an integral part of the helmet and is located on its underside. The edge profile protects both the outer shell and the inner layer from impacts from below, and in particular provides edge protection. The positioning of the recess in the edge profile offers several advantages. First, it allows for simple and discreet cable routing without compromising the helmet's structural integrity. The cable can be routed through the recess without the wearer having to damage structural components such as the outer shell, the inner layer, or the edge profile itself.Furthermore, the recess is also provided in a component that is smaller than the inner layer of the protective helmet. By arranging the recess, and thus also an additional communication system cable, at this point, the head-mounted opening itself is advantageously not obstructed by any cable routing. Preferably, the recess is located in a side area of ​​the lower edge profile, in particular in a separate side part of the lower edge profile, for example, the left part or alternatively the right part of the edge profile. The edge profile can, in principle, be securely and permanently connected to the outer shell.

[0022] According to a preferred embodiment of the protective helmet, the molded part is made of rubber. The rubber molded part offers several advantages, particularly relevant for use in a protective helmet. Rubber is an elastic and flexible material that is easily deformed, which facilitates the manual removal and reinsertion of the molded part into the recess for routing a communication system cable. This flexibility allows the molded part to be repeatedly removed and reinserted without losing its shape or function. Furthermore, the elasticity of the rubber ensures that the molded part fits snugly in the recess and conforms to its contours, resulting in an improved seal. This is especially important for preventing the ingress of wind, dirt, and moisture, thus increasing the lifespan and functionality of the protective helmet.The rubber molding can be made from various materials, including natural rubber, EPDM, nitrile rubber, neoprene, TPE, styrene-butadiene rubber, butyl rubber, silicone, or polyurethane. These materials offer the necessary flexibility and durability to meet the requirements of a protective helmet.

[0023] According to a preferred embodiment of the protective helmet, the molded part has a locking projection on its upper surface, which is preferably partially circumferential. This locking projection is dimensioned such that it extends beyond the clear opening width of the recess for the passage of a communication system cable in at least one direction. The locking projection extends beyond the clear opening width in such a way that, when the recess is closed, it engages behind an edge of the recess and holds the molded part in place. The locking projection ensures that the molded part sits securely and stably in the recess. This prevents the molded part from being lost from the recess, particularly downwards (towards the underside of the molded part and thus preferably also towards the underside of the protective helmet).The partially circumferential design of the locking lug ensures an even distribution of holding forces, increasing the stability of the component's fit within the recess. This locking lug allows for easy, tool-free removal and reinsertion of the component, simplifying helmet handling. An advantage of this design is that the helmet wearer can quickly and easily install or remove the communication system without causing structural damage to the helmet. The locking lug ensures that the component retains its shape and function even after repeated insertion and removal, improving the helmet's usability and ease of maintenance. The locking lug itself also provides an excellent circumferential edge.

[0024] In particular, one inner side of the molded part can be cut straight, while an opposite outer side has rounded corners. This can be especially advantageous if the opening for a communication system cable has an edge that is not completely closed, preferably when viewed towards the center of the helmet, thus allowing lateral insertion into the opening through the open edge. Furthermore, the molded part can have an elongated basic shape when viewed from above, i.e., it can be rectangular rather than square. A non-rotationally symmetrical design of the molded part allows for unambiguous positioning relative to the opening and simplifies insertion. The molded part has a thinner shaft section and a larger base or underside. A base or...The underside of the molded part can, analogous to the top side with its locking projections, be at least partially wider than the clear opening width of the recess (and thus have lateral projections or a protruding edge around the molded part itself), so that the edge of the recess, when viewed from below in the closed state of the recess, is engaged by the molded part and specifically its underside, in relation to the protective helmet.

[0025] According to a preferred embodiment of the protective helmet, the helmet is provided with a recessed stepped area. This recessed stepped area surrounds the opening for a communication system cable. In the closed state of the opening, the underside of the molded part is recessed within this stepped area. This means that the area of ​​the helmet containing the cable opening has a kind of depression or step in which the molded part sits when it closes the opening. Preferably, the underside of the molded part is substantially flush with the area surrounding the underside of the molded part when the opening is closed by the molded part. This design offers several advantages.First, this creates a smooth and seamless surface on the underside of the helmet, which is not only aesthetically pleasing but also improves the helmet's aerodynamics. A smooth surface minimizes drag and reduces wind noise, which is particularly beneficial at high speeds. Second, the flush placement of the underside of the molded part prevents dirt, water, or other foreign matter from accumulating in the recess, thus increasing the helmet's durability and hygiene. Third, the recessed placement of the molded part provides additional mechanical stability, as the surrounding stepped sections hold the molded part firmly in place. This reduces the likelihood of the molded part unintentionally coming loose or shifting, increasing the helmet's safety and reliability.Furthermore, the design with the stepped section allows for easy and precise assembly of the molded part, as the step guide automatically positions it correctly. This makes inserting and removing the molded part easier for the user, simplifying everyday helmet handling. Naturally, the stepped section does not need to completely surround the recess; in the case of a recess that is open on one side (without a fully enclosing edge), it is also not present there.

[0026] According to a preferred embodiment of the protective helmet, the molded part has a free space between its underside and a lateral projection extending upwards in the vertical direction of the molded part, in particular a locking projection. The vertical extent of this free space is smaller than the thickness of a corresponding edge region of the recess for the passage of a communication system cable when the recess is closed. This smaller dimension is such that, when the recess is closed by the molded part, the edge region of the recess is clamped between the underside and the lateral projection, in particular the locking projection, of the molded part.This specific design allows for a particularly firm and secure fixation of the molded part in the recess, as the reduced vertical extent of the free space provided by the molded part effectively clamps the edge of the recess. This results in improved stability and tightness of the molded part within the recess, which in turn ensures that the communication system cable is held securely and without play in the resulting, at least partial, clamped fit with the recess. The advantage of this design is that the molded part reliably maintains its position even after repeated insertion and removal, thus guaranteeing a permanent and secure connection. Furthermore, the clamping effect, achieved by the slightly undersized dimensions of the molded part compared to the recess, ensures a secure and lasting connection.Reaching its edge prevents the molded part from unintentionally detaching, which is particularly important at high speeds or with strong vibrations, such as those that can occur when riding a motorcycle. The integration of the locking protrusion further enhances this effect by additionally securing the molded part in the recess, thus further improving the handling and safety of the helmet.

[0027] According to a preferred embodiment of the protective helmet, the recess for routing a communication system cable is at least partially open on one side, preferably towards the center of the helmet. This specific design of the recess facilitates the installation and removal of a communication system, particularly a cable. The partially open side of the recess allows the cable to be inserted laterally, significantly simplifying the cable routing process. This is especially advantageous when the cable has a connector that is larger than the diameter of the cable itself, and particularly larger than the clear opening width of the recess, which could otherwise cause difficulties when routing the cable through a completely closed recess.The partially open design of the recess allows the cable, along with the connector, to be inserted laterally from the open side, without having to force the connector through a narrow opening. This reduces the risk of damage to the cable or connector and significantly simplifies installation. The recess has an edge that is not completely closed on the side in question, giving it an open U-shape when viewed from above.

[0028] It can also be advantageously provided that an edge surrounding the recess for the routing of a communication system cable has at least one projection, preferably two opposing projections, on the partially open side. These projections are designed to engage behind a widening of a shaft section of the molded part when the recess is closed, thus securing the molded part against lateral loosening towards the partially open side of the recess. The fit of the molded part in the recess when closed can therefore be further improved and made more secure. This increases the stability and safety of the molded part in the recess, particularly in the event of movements or vibrations that may occur during helmet use.The new features offer the advantage that the molded part remains securely in position even under lateral forces, which could act on the cable and, consequently, on the molded part itself. This is particularly important to ensure the reliable operation of the communication system and to prevent the cable from being unintentionally pulled out of the recess. Furthermore, this prevents the molded part from falling out while riding or in an accident, which could compromise the safety and integrity of the helmet. The protrusions thus contribute to the helmet's durability and reliability by providing an additional mechanical safeguard that holds the molded part firmly in the recess.

[0029] According to a preferred embodiment of the protective helmet, the inner layer has a channel for guiding a cable, particularly for subsequent routing after the cable has been passed through the helmet's opening. This channel is preferably located on the inner surface of the inner layer facing the helmet's interior. The channel serves to guide the cable safely and securely within the helmet, minimizing the risk of cable damage and ensuring a neat and discreet installation. This contributes to the durability and reliability of the communication system. In particular, the cable can be connected to the helmet without the need for adhesive or the provision of adhesive points.The channel is recessed into the inner layer, specifically from the inside, meaning it is open to the inside. This allows the cable to be easily inserted into the channel from the inside or, depending on its dimensions, clicked into place for a secure fit. In particular, the helmet has a space between the opening for a communication system cable and the channel, allowing for the cable to be routed freely. Alternatively or additionally, the inner layer can have a recess for a loudspeaker, preferably on the inside of the inner layer facing the helmet's interior. This recess ensures a secure and stable positioning of the loudspeaker within the helmet, resulting in improved sound quality and greater wearing comfort.The speaker is thus protected and securely in place, reducing the risk of movement or vibration while riding. The recess could theoretically extend through the inner layer, with the inside of the outer shell forming the base of the recess, or alternatively, the base of the recess could still be formed by the inner layer itself. Preferably, the cable channel terminates in the recess housing the speaker. This means the cable can be routed directly to the speaker without having to be laid loosely inside the helmet. This significantly simplifies the installation and maintenance of the communication system, as the cable is routed via the shortest possible path and without unnecessary detours.Integrating these features into the inner layer of the helmet offers several advantages, including improved usability, enhanced safety, and optimized functionality of the communication system. Precise cable routing and secure speaker positioning increase comfort for the wearer while maintaining the helmet's structural integrity. This design allows users to easily equip the helmet with a communication system or replace it as needed without damaging the structural components. This contributes to the helmet's flexibility and adaptability, which is particularly beneficial for motorcyclists who frequently rely on different communication systems or wish to use different systems throughout the lifespan of their helmet.With regard to manufacturing, it can be advantageous to provide that the channel and / or the recess can be formed during the foaming process of the inner layer. This can save manufacturing steps and simplify production.

[0030] Preferably, the molded part can have a thinning that makes it possible to guide the cable centrally through the molded part in the area of ​​the thinning, wherein the thinning in the vertical direction of the molded part is thinner than the surrounding area of ​​the molded part.

[0031] According to a further, independent aspect of the present invention, a method for manufacturing a protective helmet is proposed, which may in particular be a motorcycle helmet. In particular, the proposed method can be used to manufacture a protective helmet as previously or subsequently described.

[0032] Therefore, features described previously or subsequently only in connection with the proposed protective helmet can also be transferred to the proposed manufacturing process where technically feasible and, if necessary, adapted with regard to carrying out a process step, and thus constitute an independent embodiment of the proposed manufacturing process for a protective helmet. Likewise, it is possible that features described previously or subsequently only in connection with the proposed manufacturing process for a protective helmet can also be transferred to the proposed protective helmet where technically feasible and, if necessary, adapted with regard to a specific device feature, thus constituting an independent embodiment of the proposed protective helmet.This also applies to the proposed method for equipping a protective helmet with a communication system, which will be explained below, as well as to the proposed system comprising both a protective helmet and a communication system. The described features are also transferable across categories of claims where technically feasible, thus avoiding unnecessary repetition.

[0033] According to the proposed method for manufacturing the protective helmet, an outer shell and an inner layer, arranged inside the outer shell, are provided. The proposed method for manufacturing the protective helmet is characterized in that the protective helmet is equipped with a recess for routing a communication system cable, wherein the recess is reversibly closed by a molded part, or closed in a closed state, such that, by manually removing and reinserting the molded part, the communication system cable can be manually connected to or disconnected from the protective helmet without damaging its structural components, and the closed state of the recess is maintained after the molded part is reinserted.

[0034] For details of the components manufactured in the production process, as well as for individual process aspects, reference is also made to the preceding description of the proposed protective helmet.

[0035] In particular, the protective helmet is equipped with a molded part (especially as described above).

[0036] In particular, the area of ​​the protective helmet that provides the opening for a communication system cable, specifically the edge profile, is manufactured using an injection molding process. The opening can be incorporated directly during the injection molding process.

[0037] The inner layer is preferably produced by a foaming process in which the inner layer is foamed directly onto the inside of the outer shell.

[0038] The finishing edge profile can preferably consist essentially of materials such as PVC or hard plastics and is preferably manufactured as an injection molded part.

[0039] According to a further, independent aspect of the present invention, a method for equipping a protective helmet with a communication system is proposed, wherein the helmet may in particular be a motorcycle helmet. In this method, a previously or subsequently described protective helmet is equipped with the communication system.

[0040] According to the proposed procedure for equipping the protective helmet with the communication system, the helmet is initially in the state where the recess is closed by means of the molded part. The procedure then comprises the following steps: Removing the molded part from the recess; guiding the cable, preferably including the plug, through the recess; and closing the recess with the molded part.

[0041] The first step of the process is therefore to remove the molded part from the recess. This can be done manually without the use of tools, especially if the molded part is designed to be elastic and flexible for easy handling. After removing the molded part, the communication system cable, preferably including its connector, is fed through the now open recess. This recess is dimensioned to easily accommodate the cable without damaging any structural components of the helmet. The advantage of this design lies in the ability to retrofit the communication system without damaging the helmet. Once the cable has been fed through the recess, it is closed again with the molded part.The molded part can be designed to flexibly adapt to the cable and completely seal the opening, preventing wind, dirt, or moisture from entering the helmet. This is particularly important for protecting the electronic components of the communication system and ensuring the helmet's comfort. The reversible sealing of the opening with the molded part allows the communication system to be removed or replaced as needed without permanently altering the helmet. This increases the helmet's lifespan and allows the user to use or upgrade different communication systems. The described steps of the process thus offer a flexible, user-friendly, and safe method for equipping a protective helmet with a communication system.

[0042] According to a preferred embodiment of the method for equipping the protective helmet with the communication system, the cable is routed to a recess for receiving the loudspeaker. This specific arrangement allows for efficient and neat integration of the loudspeaker into the protective helmet, thereby improving the functionality of the communication system. The recess serves as a dedicated space for the loudspeaker, which not only simplifies installation but also ensures that the loudspeaker is firmly and securely positioned within the helmet. This prevents movement or vibration of the loudspeaker during riding that could impair sound quality.Furthermore, routing the cable to this recess, preferably along a channel in the inner layer, ensures that the cable is neatly arranged and doesn't dangle loosely inside the helmet, thus increasing the wearer's comfort and safety. Neat cable routing minimizes the risk of cable breaks or damage from constant movement or friction. In addition, this specific cable routing to the recess allows for easy maintenance and replacement of the speaker without having to disassemble the entire helmet. This is particularly advantageous for users who regularly use different communication systems or wish to replace their components.Integrating the speaker recess into the helmet's inner layer ensures optimal speaker positioning for clear and crisp sound transmission, significantly improving communication while riding. Overall, this design enhances the helmet's usability and functionality by allowing for easy and secure integration of the speaker and its associated cable.

[0043] According to a further, independent aspect of the present invention, a system comprising a protective helmet and a communication system is proposed, the helmet being, in particular, a motorcycle helmet. The proposed method includes the protective helmet described above or below. The communication system comprises a cable, preferably including a connector.

[0044] According to a preferred embodiment of the system, the cable is arranged to run through the opening in the protective helmet for the communication system cable. The cable is preferably connected at one end to a loudspeaker and at its opposite end to a control unit and / or a power supply unit of the communication system.

[0045] Further advantageous and preferred designs will be shown in the following description with reference to the figures. In the figures, which merely depict examples of implementation, show: Fig. 1 a schematic perspective view of a proposed protective helmet, from below with a partial view of the helmet interior; Fig. 2 the protective helmet made of Fig. 1, cut lengthwise so that the helmet interior is visible, the visor not shown for clarity, and a pad in one ear area cut again to reveal the area behind the pad; Fig. 3 the ear area from Fig. 2 again in an enlarged view, and in contrast to Fig. 2 now with the recess in its closed state by means of the molded part; Fig. 4 a view from below of a section of the protective helmet made of Figs. 1 to 3 , specifically with a view to the end edge profile with the recess from below, wherein the molded part is arranged to the side of the recess; Fig. 5 shows the protective helmet in the same representation as in Fig. 4 only with a molded part inserted into the recess; Fig. 6 shows an embodiment of a proposed system with a proposed protective helmet supplemented by a communication system, wherein basically the same cutout according to Fig. 4 and Fig. 5 Figure 7 shows a further embodiment of a proposed system with a proposed protective helmet supplemented by a communication system, in the same representation and situation as in Figure 7. Fig. 6 , where a thicker cable is used compared to Fig. 6 is provided for; and Fig. 8 a molded part of the proposed protective helmet or proposed system, as shown in the illustrations according to Figs. 1 to 7 used or usable, namely according to view a) of the Fig. 8 in a front view of the inside of the molded part, according to view b) in a cut view according to section line b from view a) and shown in slight perspective, as well as according to view c) in a cut view according to section line c from view a) and shown in slight perspective. In Fig. 1 A protective helmet 1, in the form of a motorcycle helmet, is shown in a perspective view slightly from below and looking at the left side of the helmet 1. For protection, a wearer can put on the helmet 1 by placing their head through the head opening 2 on the underside 4 of the helmet 1, opposite the top 3. On the front 6, opposite the back 5 of the helmet 1, the helmet 1 has a visor 7, through which the wearer can see when wearing it. The helmet interior allows the head to see through the arranged space. In the illustration according to Fig. 1 The direction of view x is therefore directed to the left.

[0046] Since in Figs. 1 to 7 Basically the same protective helmet 1 is shown (in Fig. 6 as well as Fig. 7(each equipped with a different communication system), the following description can be applied equally to all the figures mentioned. Fig. 8 This, in turn, is only a further, more detailed, fundamental component of the protective helmet 1 according to Figs. 1 to 7 shown separately in isolated views, which will be discussed in more detail later.

[0047] The protective helmet 1 has an outer shell 9. The outer shell 9 serves to protect the helmet wearer from external forces acting from an external environment U and specifically to distribute such so-called impact forces, which can occur, for example, in a motorcycle crash. A [missing information] is connected to the outer shell 9, on the inner side 9i of the outer shell 9. Fig. 1 not recognizable, but in Fig. 2 and Fig. 3The visible inner layer 10 is arranged, which is sometimes also called the inner shell. This inner layer 10 in turn serves to dampen the aforementioned impact forces.

[0048] The inner layer 10 therefore typically consists primarily of a plastic foam, for example expanded polystyrene (EPS). Alternatively, other materials, such as expanded polypropylene (EPP) or expanded polyethylene (EPE), could also be used. The inner layer may contain or consist primarily of particle foam.

[0049] The outer shell 9, in turn, can be made of a durable and impact-resistant material. For example, the outer shell 9 can consist primarily of thermoplastic materials such as polycarbonate (PC), acrylonitrile butadiene styrene (ABS), or glass fiber reinforced plastic (GFRP). Alternatively, other materials, such as carbon fiber reinforced plastic (CFRP) or polyamide (PA), can also be used. The use of metallic materials for the outer shell 9 is also conceivable; for example, the outer shell 9 can also be made of steel or consist primarily of steel for certain applications. Imprints, laminations, and the like can be arranged or applied to the outer surface 9a of the outer shell 9, which, of course, do not necessarily have to be made of the aforementioned materials.

[0050] The inner layer 10 is preferably produced by a foaming process, in which the inner layer 10 is directly applied to the inside of a - in Fig. 2 and Fig. 3 The inner surface 9i of the outer shell 9 is foamed. The particle foam is introduced into a mold that already contains the outer shell 9, so that the foam forms a firm bond with the inner surface 9i of the outer shell 9 during the expansion process.

[0051] During the foaming process, the inner layer 10 is produced from a particle foam, with corresponding recesses, such as a channel 11 for guiding a cable 12 and a recess 13 for receiving a loudspeaker (see also Fig. 2 , Fig. 3 , Fig. 5 , Fig. 6 and Fig. 7), preferably formed directly during the foaming process by excluding the corresponding areas from the foam. Alternatively, it would be conceivable to form the recesses subsequently after the foaming process. The inner layer 10 has the aforementioned recesses on its inner side 10i facing the helmet interior 8.

[0052] The specific recesses serve, on the one hand, to accommodate a loudspeaker in recess 13, which is a component of the communication system of the protective helmet 1, and on the other hand, to guide the cable 12 to the loudspeaker (not shown) in channel 11. Channel 11 terminates in recess 13 for the loudspeaker.

[0053] At the in Figs. 1 to 5The depicted and therefore preferred protective helmet 1 is a type of universal protective helmet 1, which is not yet equipped with a communication system at the factory. Rather, it is up to the user, i.e., the future helmet wearer, to add an individually desired communication system (as shown in the illustrations according to Fig. 6 and Fig. 7 (already done). For this purpose, he can obtain various models of loudspeakers that fit into the aforementioned recess 13 and equip the protective helmet 1 with them. Such loudspeakers then also need to be wired, for which the cable 12 must, on the one hand, be regularly connected to the loudspeaker via its end plug, and on the other hand, be connected at its opposite end to a control unit or power supply unit located elsewhere on the protective helmet 1, either already or yet to be connected.

[0054] In the intended state of use of the protective helmet 1, components of communication systems connected to the protective helmet 1, such as the aforementioned cable 12 and the loudspeaker, are preferably at least partially concealed. For this purpose, it is advantageous to utilize the various pads 14, which primarily serve the wearing comfort of the helmet wearer. The recesses in the form of the depression 13 for the loudspeaker and the channel 11 are therefore substantially concealed towards the helmet interior 8 by the pads 14, or, in the embodiment shown here and thus preferred, by the multiple pads 14. The pads 14 are detachably connected to the inner layer 10, so that the helmet wearer can detach and reconnect the pads 14. The pads 14 are shown in the illustrations of the Fig. 2 and Fig. 3 Partially cropped to reveal the speaker area behind it. Fig. 1In the right ear area 15, the speaker area located behind the padding 14 is indicated by the dashed circle. On the opposite ear, not in Fig. 1 In the left ear area, visible from the inside, there is also a corresponding speaker area. This speaker area is shown in the partially cutaway views according to... Fig. 2 and Fig. 3 The view is now clear.

[0055] In order to equip the protective helmet 1 with an additional communication system, the helmet wearer must make adjustments to the one in Fig. 1The protective helmet 1, which is basically usable even without an additional communication system, is to be modified. While, according to the prior art, this often involved the helmet wearer damaging structural components of the protective helmet 1, such as the inner layer 10 or an underside edge profile 16 of the protective helmet 1, in order to create space for the cable 12 to connect the components of the communication system and to guide that cable 12 into the protective helmet 1, behind the padding, or into or behind the inner layer 10, this is no longer necessary according to the proposed method.As proposed, the helmet wearer can proceed as follows to equip his protective helmet 1 with a communication system, either because the protective helmet 1 does not yet have a communication system or because an existing communication system, possibly previously supplemented, needs to be completely replaced or checked with regard to some components.

[0056] To add a communication system to his protective helmet 1 without a communication system, the helmet wearer first removes a molded part 17, which in the present and preferred embodiment is a rubber molded part, from a recess 18 on the underside 4 of the protective helmet 1. The recess 18 is therefore initially closed with the molded part 17, as is the case, for example, in Fig. 1 , in Fig. 3 and in Fig. 5The illustration shows that the protective helmet 1 is also in the closed state of the recess 18 by means of the molded part 17. Removing the molded part 17 results in an open state of the recess 18, which in turn is Fig. 2 It is evident which Fig. 2 The curved arrow indicates how the molded part 17 can be reinserted into the recess 18, and what open state it further represents. Fig. 4 is shown.

[0057] The molded part 17, whose properties are described continuously, is shown separately in Fig. 8 , shown in the three views a), b), and c), so that continuously also on Fig. 8 Reference can be made to this. View a) is the Fig. 8A front view of an inner side 17i of the molded part 17 is shown, and views b) and c) are each perspective views, with the molded part 17 shown in section according to the section lines marked b and c in view a). In the perspective views b) and c) of the Fig. 8The molded part 17 is thus shown in perspective, with a view of the (in view c) cut-out) top surface 17o, the inside surface 17i, and a front surface 17v connecting the inside surface 17i to an opposite outside surface 17a of the molded part 17. The directional indications regarding the molded part 17 refer to its intended use when, as mentioned, the molded part 17 closes the recess 18. The inside surface 17i is the side facing the helmet interior 8, while the outside surface 17a is the opposite side, which is generally oriented towards the external environment U. These two sides, in the form of the inside surface 17i and outside surface 17a, are connected by the front surface 17v, which, in the assembled state, faces forward in the direction x, and by a back surface 17r opposite the front surface 17v.In the assembled state, the underside 17u of the molded part 17 is facing downwards and therefore also directly towards the external environment U, while the top side 17o is arranged opposite it.

[0058] Removing the molded part 17 from the recess 18, i.e., changing the part in Fig. 1 or Fig. 3 or Fig. 5 depicted state in the state according to Fig. 2 or Fig. 4 , can be done easily by hand by the helmet wearer either releasing the molded part 17 downwards from its engagement with the recess 18 from the protective helmet 1 (from the underside 4 downwards) or inwards towards the helmet interior 8 or a combination of both movements.

[0059] The molded part 17, in this case designed as a rubber molded part, is elastic and flexible. Suitable materials include, but are not limited to: natural rubber, EPDM (ethylene propylene diene monomer rubber), nitrile rubber (NBR), neoprene, TPE (thermoplastic elastomers), styrene-butadiene rubber (SBR), butyl rubber (IIR), silicone, and polyurethane (PU). These materials offer the necessary flexibility and durability to allow the molded part 17 to be repeatedly removed from and reinserted into the recess 18 without losing its shape or function.

[0060] Due to the elasticity of the molded part 17, it can be easily deformed to remove it from and reinsert it into the recess 18. This also ensures a secure fit of the molded part 17 in the recess 18, possibly supported by the material's restoring forces. In the closed state, the molded part 17 is positively engaged in the recess 18, and, depending on the selected dimensions, an interference fit can also be achieved, at least partially, compared to the dimensions of the recess 18.

[0061] To allow removal of the molded part 17 from the recess 18, the helmet wearer must first detach at least the padding 14, which, in the assembled state, is located next to or inside the recess 18 that is still closed by the molded part 17. By detaching the padding 14, which is connected to the inner layer 10 or, alternatively, if applicable, to the inner surface 9i of the outer shell 9, the channel 11 and the recess 13 are also exposed (see, for example, the figure). Fig. 2 and Fig. 3 or also Fig. 4 and Fig. 5 including the still mounted pad 14, i.e. connected to the inner layer 10, wherein the pad 14 is in Fig. 2 and Fig. 3 (partially cut out).

[0062] After removing the padding 14 and the molded part 17 as described above, the helmet wearer can then guide the cable 12 of their communication system through the exposed recess 18, which is in its open state at that time. Since the cable 12 has a connector (not shown) at its end, which typically has a larger cross-sectional area perpendicular to the longitudinal direction of the cable 12 than the cable itself, the connector is often the limiting factor in how easily it can be guided through cutouts or recesses.If the corresponding plug is not too large for the corresponding extensions of the recess 18 in both transverse directions, i.e. the corresponding clear opening widths, the cable 12 together with the plug can simply be guided from below through the recess 18, and thus from the outside, to the inside, i.e. into the inner area of ​​the protective helmet 1 and specifically behind the, i.e. above the, end edge profile 16.

[0063] Should the plug be too large for the corresponding clear opening widths of the recess 18 in its transverse directions, it can be advantageously exploited that the recess 18 is only closed in three of the four mutually perpendicular transverse directions, i.e., has a closed edge 19, while the recess 18 is at least partially open, i.e., edgeless, in the fourth direction, namely towards the center of the helmet or the helmet interior 8. Consequently, the edge 19 of the recess 18 is not closed in that fourth direction towards the center of the helmet. Viewed from above, the recess 18 thus has a U-shape open on one side. This works out well. Fig. 2 as well as Fig. 4This circumstance can therefore be used to advantage if the plug were too large, or otherwise regardless of the plug size, in order to guide or place the cable 12 together with the plug laterally, basically starting from the helmet interior 8, into the recess 18 and thus carry out the step of guiding the cable 12 together with the plug through the recess 18.

[0064] Following this, cable 12 is routed to channel 11, placed inside, or, if necessary, clicked into place. It then continues to recess 13 for the loudspeaker and is connected there to the loudspeaker, or more generally, to the communication system. Cable 12 then runs through the opening 18 of the protective helmet 1, and its end is connected as intended to the loudspeaker, while its opposite end is connected to a control unit and / or a power supply unit of the communication system (this connection to the control unit or power supply unit was either already in place or still needs to be made by the helmet wearer).In this way, the helmet wearer has essentially already achieved the goal of equipping his protective helmet 1, which was previously factory-fitted without the corresponding communication system, with the communication system and thus creating a system for himself comprising the protective helmet 1 and the communication system. While it is described that the cable 12 undergoes the aforementioned further arrangement and connection steps following the step of guiding the cable 12 through the recess 18, it is also stated that when the cable 12 is inserted laterally into the recess 18 from inside the helmet 8, the aforementioned connections (e.g., of the cable 12 to the loudspeaker) and positioning (e.g., of the cable 12 in the channel 11) are carried out either before or simultaneously with the step of guiding the cable 12 through the recess 18.

[0065] To restore the protective helmet 1 to a comfortable and usable state, the helmet wearer next reattaches the previously detached pads 14 to the inside 10i of the inner layer 10. He then proceeds to reclose the recess 18 with the molded part 17, so that the opening resulting from the removal of the molded part 17 (viewed from the outside) up to (behind or above) the end edge profile(s) 16, which would not be adequately closed simply by inserting or guiding the cable 12 through, is again satisfactorily closed using the molded part 17. This step thus returns the recess 18 to its closed state, so that this closed state of the recess 18 is maintained even after the molded part 17 is reinserted.

[0066] This state, in which the cable 12 was on the one hand guided through the recess 18, i.e., the communication system was added to the protective helmet 1, and on the other hand the recess 18 was closed again by manually reinserting the molded part 17, is in Fig. 6 as well as Fig. 7 Two alternative representations are shown. Both representations show a section of the protective helmet 1 from below, specifically the underside 4, with the end edge profile 16 and the recess 18 shown from below. The reinserted molded part 17 is thus also shown with a view of its underside 17u. In the embodiment according to Fig. 6 The cable 12 is comparatively relatively thin, so that the cable 12 lies between the edge 19 of the recess 18 and - in this case the Fig. 5- is clamped to the outer surface 17a of the molded part 17 or enclosed by the edge 19 and the molded part 17 accordingly. Here, the elasticity of the molded part 17, which is designed as a rubber molded part, is advantageous, so that the material conforms to the cable 12 as best as possible or surrounds the cable 12.

[0067] In the alternative according to Fig. 7 The cable 12 of the corresponding communication system is slightly thicker than in the embodiment shown in the illustration. Fig. 6Accordingly, the molded part 17 is adapted before the step of closing the recess 18, since in this example the cable 12 should not pass between the edge 19 of the recess 18 and the molded part 17. In this embodiment, the helmet wearer trims (or adapts) the molded part 17 accordingly to guide the cable 12 centrally through the molded part 17 itself. As a result, the cable 12 is no longer in contact with the edge 19 in the area of ​​the recess 18, but is exclusively surrounded or enclosed by the molded part 17 itself. The visible line running towards the outer side 17a of the molded part 17 (towards the outer environment U) indicates a slot in the molded part 17.The helmet wearer can create this slit himself, in order to achieve a kind of partial division and spreading of the molded part 17. For this purpose, a pre-defined feature such as a weakening, marking, or perforation may be provided. Alternatively, the molded part 17 may already be slit accordingly, in which case, even without a cable 12 passing through it, the molded part 17 can still adequately fulfill its function, such as sealing the recess 18, when closing the recess 18. To route the cable centrally through the molded part 17, as shown in... Fig. 7To enable the material to be guided through (or guided laterally along the slot to the center and positioned there centrally), the molded part 17 has a corresponding thinning 20. The material of the molded part 17 is thinner in the area of ​​the thinning 20 in the vertical direction of the molded part 17 (direction running from the underside 17u to the top side 17o) than in the area surrounding the thinning 20. As shown in Fig. 8 , in views b) and c), and further in Fig. 2As can be seen particularly well, the molded part 17 has a recess 21 on its upper surface 170. The corresponding area of ​​the thinning 20 can either be cut out, possibly partially, or simply cut or pierced to guide the cable 12 centrally through the molded part 17 or to position it centrally there when the molded part 17 is reinserted into the recess 18. Although the helmet wearer supplements the communication system in the described embodiment according to Fig. 7 So, if the molded part 17 is processed and possibly cut into or even cut off and removed a part, the structural components of the protective helmet 1 remain unprocessed and, above all, non-destructive.

[0068] The proposed protective helmet 1 is therefore particularly advantageous in that it has the recess 18, which is designed for the routing of the cable 12 of the communication system. The recess 18 is designed to be reversibly closed with the molded part 17, as described, and, in the closed state of the recess 18, is reversibly closed with the molded part 17 in such a way that the cable 12 can be connected to or disconnected from the protective helmet 1 by manually removing and reinserting the molded part 17, without damaging any structural components of the protective helmet 1.

[0069] Both before the addition of a communication system and after the reinsertion of the molded part 17 into the recess 18, the functionality of the recess 18, sealed by the molded part 17, is guaranteed. Thus, on the one hand, no structural components of the protective helmet 1 are affected by the addition of the communication system, as no modifications or cutouts are necessary for components such as the inner layer 10. On the other hand, the permanently sealed state of the recess 18 ensures that no wind can penetrate the recess 18 into the area behind it, and that the ingress of dirt and moisture is also prevented, which is of central importance, especially when the protective helmet 1 is designed as a motorcycle helmet.Increased wind resistance could have a particularly negative acoustic impact on the areas behind the opening created by the recess 18 (which could also negatively affect driving safety). Furthermore, moisture ingress would damage electronic components, such as the communication system, or lead to material damage, especially to the textiles, including damage to the connections between the regular textile padding 14 and the inner layer 10.

[0070] The proposed recess 18 is arranged on the underside 4 of the protective helmet 1, specifically on the underside 4 surrounding the head opening 2. The recess 18 is located in a side region of the underside edge profile 16. In the present embodiment, the edge profile 16 has, as shown in Fig. 1The helmet has a left part 16l, a right part 16r opposite it, and a rear part 16h. The end edge profile 16 is fixedly connected to the outer shell 9 of the helmet 1. The recess 18 is located in the separate side part in the shape of the left part 16l of the lower end edge profile 16.

[0071] The edge profile 16 is made primarily of PVC, which has rubber-like properties and thus offers a degree of flexibility and shock absorption. Alternatively, it could also be made of a hard plastic that is robust and durable. The edge profile 16 is an injection-molded part in which the recess 18 is already incorporated into the mold during manufacturing, eliminating the need for any subsequent machining. This allows for a precise and perfectly fitting recess 18, ideally suited for routing the cable 12 of a communication system. Manufacturing is thus efficient. The edge profile 16 provides a clean, aesthetically pleasing finish that protects the edges of the outer shell 9 and the inner layer 10.

[0072] The molded part 17 has a partially circumferential locking projection 22 on its upper surface 17o, which is dimensioned such that it extends in three mutually perpendicular directions beyond the clear opening width of the recess 18 or the edge 19 of the recess 18 on the inside of the recess 18 opposite the outer environment U (the inner area of ​​the protective helmet 1) and thus engages behind the edge 19 of the recess 18 in order to hold the molded part 17 in the recess 18.

[0073] The molded part 17 has a thinner shaft section 23 (through which the section c according to view a) in Fig. 8(runs) and a larger base 24 or a larger underside 17u. The base 24 or the underside 17u of the molded part 17 is also wider than the clear opening width of the recess 18, analogous to the top 17o (with the locking projections 22 there), so that the edge 19 of the recess 18, even when viewed from below in relation to the protective helmet 1, is engaged by the molded part 17 and specifically its underside 17u in the closed state of the recess 18.

[0074] The inner surface 17i of the molded part 17 is cut straight (specifically, when the recess 18 is closed, facing the helmet interior 8), while the opposite outer surface 17a has rounded corners. Furthermore, the basic shape is elongated in plan view, i.e., more rectangular than square. The non-rotationally symmetrical design of the molded part 17 ensures unambiguous positioning relative to the recess 18 and simplifies the insertion of the molded part 17 into the recess 18.

[0075] As described, the recess 18 does not have a closed edge 19 in a transverse direction, namely inwards towards the center of the helmet (cf. Fig 4 : downwards in the representation according to Fig. 4), so that the molded part 17 can be cut straight towards that edgeless side without significantly impairing its insertion into the recess 18. The opposite rounded corners can simplify the insertion of the molded part 17 into the recess 18 (see again Fig. 4 or also Fig. 2 (with the insertion movement indicated there by a curved arrow). This also applies to the shaft section 23 of the molded part 17, as shown especially in view c) of the Fig. 8This can be seen. Here too, with regard to lateral insertion into the recess 18, rounded corners are present in the direction of the recess 18, thus simplifying this lateral insertion. Opposite, towards the center of the helmet, the shaft section 23 is slightly widened again towards the end, so that this final widening 25, as well as a preceding widening 26 of the shaft section 23 in the direction of the center of the helmet, ensures that the molded part 17 can be securely held in its position closing the recess 18 when the recess 18 is closed.

[0076] Around the recess 18, as shown in the illustration according to Fig. 4It can be seen that a recessed stepped area 27 is arranged in which the foot 24 or the underside 17u of the molded part 17 is recessed in the closed state of the recess 18. The foot 24 or the underside 17u is essentially flush with the area surrounding the foot 24 or the underside 17u, except on the edgeless side.

[0077] Between the base 24 (or underside 17u) and a lateral projection extending upwards in the vertical direction of the molded part 17 (from the underside 17u to the top 17o), in this case the locking projection 22, the molded part 17 has a free gap 28. The vertical extent of the free gap 28 can be smaller than the thickness of the corresponding edge region of the recess 18, so that the edge region of the recess 18 is clamped between the base 24 (or underside 17u) and the locking projection 22 when the recess 18 is closed. A press fit can be achieved by this slightly smaller dimensioning of the molded part 17 compared to the recess 18 or its edge region.

[0078] The recess 18 is partially open towards the center of the helmet, as mentioned. The rim 19 surrounding the recess 18 has two opposing projections 29 on the partially open side (see figure). Fig. 4 ). These projections 29 are designed to accommodate the widening 26 of the shaft section 23 of the molded part 17 (cf. Fig. 8 , especially views b) and c)) in the closed state of the recess 18 to engage behind it and to secure the molded part 17 against lateral loosening in the direction of the partially open side of the recess 18.

[0079] A proposed method for manufacturing the protective helmet 1 comprises providing the outer shell 9 and the inner layer 10. The inner layer 10 is located inside the inner surface 9i of the outer shell 9 and is, in particular, foamed onto the inner surface 9i. As part of the method, the protective helmet 1 is equipped with a recess 18 for the passage of a cable 12 of a communication system by manufacturing the end edge profile 16 as an injection-molded part in a single manufacturing step together with the recess 18 and attaching this end edge profile below the outer shell 9 and inner layer 10 of the protective helmet 1. The corresponding recess 18 is designed so that it can be reversibly closed with the molded part 17. The molded part 17 closes the recess 18 in a closed state. The molded part 17 can be manually removed from the recess 18 and reinserted.This allows the communication system cable 12 to be manually and non-destructively connected to or disconnected from the protective helmet 1. After reinserting the molded part 17, the recess 18 remains closed again.

[0080] The reversible closure of the recess 18 with the molded part 17 ensures that no structural components of the protective helmet 1 are damaged. This contributes to the durability and safety of the protective helmet 1. The recess 18 allows for easy and non-destructive installation and removal of the communication system, which facilitates the maintenance and adjustment of the protective helmet 1. This is particularly advantageous for helmet wearers who frequently use or wish to exchange different communication systems. Reference symbol list 1 protective helmet 26 Widening (of the shaft section of the 2 Head opening molded part) 3 Top side (of the helmet) 27 recessed step area (of the left part of the finishing edge profile) 4 Underside (of the helmet) 5 back (of the helmet) 28 free space 6 Front (of the helmet) 29 projection 7 visor 8 Helmet interior U external environment 9 outer shell x View direction 9a outer surface (of the outer shell) 9i Inside (of the outer shell) 10 inner layer 10i Inside (of the inner layer) 11 channel 12 Cable 13 Recess (for a speaker) 14 pad 15 ear area 16 Edge profile 16h rear part (of the edge profile) 16l left part (of the edge profile) 16r right part (of the edge profile) 17 Molded part 17i Inside (of the molded part) 17a Outside (of the molded part) 17v Front side (of the molded part) 17r reverse side (of the molded part) 17u Underside (of the molded part) 17o Top side (of the molded part) 18 recess 19 edge (of the recess) 20 Thinning (of the molded part) 21 Recess (of the molded part) 22 Latching projections (of the molded part) 23 Shaft section (of the molded part) 24 Foot (of the molded part) 25 final widening (of the shaft section of the molded part)

Claims

1. Protective helmet (1), in particular a motorcycle helmet, comprising: - an outer shell (9) for distributing impact forces, wherein the outer shell (9) has an outer surface (9a) facing the external environment and wherein the outer shell (9) has an inner surface (9i) opposite the outer surface (9a) and facing a helmet interior (8); and - an inner layer (10) for damping impact forces, wherein the inner layer (10) is arranged inside the inner surface (9i) of the outer shell (9); characterized by the fact thatThe protective helmet (1) has a recess (18) for the passage of a cable (12) of a communication system, which recess (18) is designed to be reversibly closed by a molded part (17), or is closed in a closed state of the recess (18), such that, by manually removing and reinserting the molded part (17), the cable (12) of the communication system can be manually connected to or detached from the protective helmet (1) without damaging any structural components of the protective helmet (1), and the closed state of the recess (18) is maintained after the molded part (17) has been reinserted.

2. Protective helmet (1) according to claim 1, wherein the recess (18) is arranged on an underside (4) of the protective helmet (1).

3. Protective helmet (1) according to claim 1 or 2, wherein an underside end edge profile of the protective helmet (1) has the recess (18).

4. Protective helmet (1) according to one of claims 1 to 3, wherein the molded part (17) is a rubber molded part.

5. Protective helmet (1) according to one of claims 1 to 4, wherein the molded part (17) has on its upper side a locking projection (22), preferably partially circumferential, which locking projection (22) is dimensioned such that the locking projection (22) extends beyond at least in one direction a clear opening width of the recess (18) such that the locking projection (22) engages behind an edge (19) of the recess (18) in the state of the recess (18) being closed by means of the molded part (17) and holds the molded part (17) in the recess (18).

6. Protective helmet (1) according to one of claims 1 to 5, wherein the recess (18) is surrounded by a stepped area (27), in which stepped area (27) a bottom surface (17u) of the molded part (17) is recessed in the recess (18) when closed by means of the molded part (17); wherein, preferably, the bottom surface (17u) is substantially flush with an area surrounding the bottom surface (17u) when the recess (18) is closed by means of the molded part (17).

7. Protective helmet (1) according to one of claims 1 to 6, wherein the molded part (17) has a free distance (28) between a bottom surface (17u) and a lateral projection extending upwards in the vertical direction of the molded part (17), in particular the locking projection (22), wherein a vertical extent of the free distance (28) is dimensioned to be smaller than a thickness of an edge region of the recess (18) corresponding in the closed state of the recess (18) by means of the molded part (17), such that the edge region of the recess (18) is clamped between the bottom surface (17u) and the lateral projection, in particular the locking projection (22), of the molded part (17) in the closed state of the recess (18).

8. Protective helmet (1) according to one of claims 1 to 7, wherein the recess (18) is at least partially open to one side, preferably towards the center of the helmet.

9. Protective helmet (1) according to claim 8, wherein an edge (19) surrounding the recess (18) has at least one projection (29), preferably two opposing projections (29), on the partially open side, wherein the projection (29), in particular the projections (29), is / are configured to engage behind a widening of a shaft section (23) of the molded part (17) in the recess (18) closed by means of the molded part (17) and thus secures the molded part (17) against lateral loosening in the direction of the partially open side of the recess (18).

10. Protective helmet (1) according to any one of claims 1 to 9, wherein the inner layer (10) has a channel (11) for guiding the cable (12), in particular for subsequent guidance following the intended passage of the cable (12) through the recess (18) of the protective helmet (1), preferably on an inner side (10i) of the inner layer (10) facing the helmet interior (8); and / or wherein the inner layer (10) has a recess (13) for receiving a loudspeaker, preferably on an inner side (10i) of the inner layer (10) facing the helmet interior (8); wherein, preferably, the channel (11) for guiding the cable (12) opens into the recess (13) for receiving the loudspeaker.

11. Method for manufacturing a protective helmet (1), preferably a protective helmet (1) according to one of claims 1 to 10, wherein an outer shell (9) and an inner layer (10), arranged inside an inner surface (9i) of the outer shell (9), are provided, characterized by the fact that The protective helmet (1) is equipped with a recess (18) for the passage of a cable (12) of a communication system, wherein the recess (18) is arranged to be reversibly closed by means of a molded part (17), or is closed in a closed state of the recess (18), such that, by means of manually removing and reinserting the molded part (17), the cable (12) of the communication system can be manually connected to or detached from the protective helmet (1) as intended, without causing damage to the structural components of the protective helmet (1), and wherein, after reinserting the molded part (17), the closed state of the recess (18) is maintained.

12. Method for equipping a protective helmet (1) according to any one of claims 1 to 10 with a communication system, wherein the protective helmet (1) is in the state of the recess (18) being closed by means of the molded part (17), comprising the following steps: - removing the molded part (17) from the recess (18); - guiding the cable (12), preferably including the connector, through the recess (18); and - closing the recess (18) with the molded part (17).

13. Method according to claim 12, characterized by the fact that the cable (12) is led to a / the recess (13) for receiving a / the loudspeaker.

14. System comprising a protective helmet (1) according to one of claims 1 to 10 and a communication system, wherein the communication system comprises a cable (12), preferably including a plug.

15. System according to claim 14, wherein the cable (12) is arranged to run through the recess (18) of the protective helmet (1) for the passage of the cable (12) of the communication system; wherein, preferably, the cable (12) is connected at one end to a loudspeaker and at its opposite end to a control unit and / or a power supply unit of the communication system.

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