Removable helmet cover and manufacturing method

Abstract

To provide a removable helmet cover and a manufacturing method.SOLUTION: Provided is a helmet cover (100) comprising a single integrated shell assembly (202) having a receiving cavity (208), an inner surface (204), and an outer surface (206). The receiving cavity is configured such that an inner surface of the single integrated shell assembly is in contact with an outer surface of a helmet (102). The single integrated shell assembly conformably and removably covers the outer surface of the helmet, the helmet cover.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims priority to U.S. Patent Application No. 17 / 664,892, filed May 25, 2022, which in turn claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 192,927, filed May 25, 2021, the contents of which are incorporated herein by reference in their entireties.

[0002] (Technical field) The present invention is directed to an injection molded article and method of making the same, which is a helmet cover for a protective helmet, and more specifically, an interchangeable helmet cover for enhancing the aesthetic appearance of helmets used in the military, construction, manufacturing, and / or competitive sports such as American football, baseball, lacrosse, hockey, horseback riding, skiing, snowboarding, and the like. [Background technology]

[0003] Helmets are standard protective equipment in many athletic, industrial, and military applications. For example, helmets are commonly used in competitive sports such as American football, baseball, lacrosse, hockey, horseback riding, skiing, and snowboarding, and as personal protective equipment in construction, manufacturing, and military contexts.

[0004] Each helmet is uniquely shaped to accommodate the user's head size as well as provide protection against the specific crash risks associated with the application. Helmets often include interior cushioning and exterior hardware such as a face mask, chin strap, and trim. In addition, helmets are designed to meet any safety requirements and regulations associated with the particular application.

[0005] Due to the various design and safety considerations associated with creating and manufacturing helmets, helmets are expensive safety equipment. As a result, players and other users are typically issued only a single helmet for practice, training, or competition. Even when helmets are used in industries and programs with larger budgets, such as professional teams, universities, or the military, the cost of a new helmet limits the number of helmets issued to each user.

[0006] At the same time, users may desire to change the appearance of their uniforms for a variety of reasons, including featuring a "throwback" uniform, supporting a particular cause, honoring a particular person or organization, or celebrating a particular achievement or involvement in a notable athletic event. For these purposes, there are few options available to users who wish to change the appearance of their helmets. Users can purchase additional helmets, but as explained above, this is not an economical choice and most organizations cannot afford to pursue this option.

[0007] Helmets can also be painted, covered with adhesive labels or patches, or covered with wraps or multi-piece covers. Each option has drawbacks. For example, painting helmets is time-consuming and expensive and generally requires the use of trained personnel to achieve a consistent appearance for all helmets. In addition, painting generally cannot be reversed to restore helmets to their original color unless the helmets are repainted, which requires additional time and expense. Adhesive logos and stickers do not require a high skill level, but the cost varies with the quality and size of the sticker. Additionally, due to the size and contours of the helmet, the size and shape of the sticker are limited to ensure that the sticker can be applied without wrinkles, air holes, or creases. As a result, it is not possible to change the overall appearance of the helmet using this method. Wraps and other multi-piece covers are difficult to install accurately and have clearly visible seam lines if they are applied incorrectly. While some wraps are available as a single piece, they also use adhesives or heating methods for application. Adhesive wraps are difficult to apply because the product can fold and adhere to itself, and the heat and tensioning techniques require professional application which is again expensive and time consuming.

[0008] In any of these applications, if the product is not applied with skill and precision, the end result will not be visually pleasing as there may be helmet-to-helmet variations, wrinkles, creases, and improper orientation. Summary of the Invention [Means for solving the problem]

[0009] The present invention is directed to an injection molded article and method of making the same, which is a helmet cover for a protective helmet, and more specifically, an interchangeable helmet cover for enhancing the aesthetic appearance of helmets used in the military, construction, manufacturing, and / or competitive sports such as American football, baseball, lacrosse, hockey, horseback riding, skiing, snowboarding, and the like.

[0010] Helmet covers according to the present disclosure are formed from a single piece and therefore do not require assembly. Although such helmet covers are formed from a single piece, they still maintain a comfortable fit that mimics the shape of large, irregular, and contoured helmet configurations used in athletics, industrial, and military applications. These helmet covers are designed to conformably attach to helmets and therefore can be applied without adjustments or fasteners. Because such helmet covers are formed from a single piece, they can be applied without visible seams, wrinkles, vents, and / or folds. These helmet covers can be quickly applied and removed without skill or damaging or altering the helmet surface. These helmet covers can be produced in a variety of colors and designs and can include stickers of almost any size, shape, and / or color. These helmet covers do not interfere with the function of the helmet and can withstand normal use. The design and manufacture of the helmet covers also allows them to be offered at an economical price, thereby increasing the number of times a team can change the design of its helmet cover.

[0011] As described herein, thermoplastics are used to form injection-molded articles and are employed in the manufacturing process. For convenience, reference may be made to specific types of thermoplastics, such as thermoplastic polyurethane ("TPU"), but it should be understood that the present invention encompasses all suitable thermoplastics as described herein. The present invention provides a helmet cover. The helmet cover includes a unitary shell assembly including a receiving cavity, an inner surface, and an outer surface. The receiving cavity is configured such that the inner surface of the unitary shell assembly is configured to contact the outer surface of the helmet, and the unitary shell assembly is configured to conformably and removably cover the outer surface of the helmet.

[0012] The present invention also provides a method for manufacturing a helmet cover. The method includes providing a polymer injection unit including: (A) (i) a barrel-mounted screw assembly, the barrel-mounted screw assembly including a screw mounted within a barrel; (ii) a processing space, the processing space including a distal end and a proximal end; and (iii) one or more nozzles in fluid communication with the processing space, the one or more nozzles being disposed at the distal end of the processing space. The method for manufacturing a helmet further includes (B) providing an injection mold tool, the injection mold tool including a mold cavity in fluid communication with the one or more nozzles, the injection mold tool being configured to integrally form a helmet cover. The method for manufacturing a helmet further includes (C) introducing a polymer material into the processing space. The helmet manufacturing method further includes (D) melting the polymeric material in the processing space, where the melting is achieved by using a screw mounted in the barrel to mix the polymeric material, applying a heat source, bringing the polymeric material to a first predetermined temperature, and creating a predetermined back pressure. The helmet manufacturing method further includes (E) injecting a volume of the polymeric material into the mold cavity through one or more nozzles, where the volume of the polymeric material is sufficient to fill the mold cavity. The helmet manufacturing method further includes (F) cooling the polymeric material in the mold cavity to a second predetermined temperature. The helmet manufacturing method further includes (G) extracting the polymeric material in the mold cavity from the injection mold tool to provide a helmet cover.

[0013] The method for manufacturing a helmet cover optionally further includes (B) providing an injection mold tool, where providing the injection mold tool can further include (i) scanning a helmet to obtain a helmet geometry file, (ii) modifying the helmet geometry file to form a helmet cover geometry file, (iii) printing a three-dimensional helmet cover prototype, (iv) adjusting the helmet cover geometry file, and (v) generating the injection mold tool using the helmet cover geometry file. Modifying the helmet geometry file can include one or more of: (a) manipulating the size and / or shape of the helmet cover, (b) modifying the structure of the helmet cover, (c) adding one or more gripping members to the helmet cover, and / or (d) adding a plurality of micro-perforations to the helmet cover. Additionally, adjusting the helmet cover geometry file can include providing an improved fit of the helmet cover compared to the three-dimensional helmet cover prototype. The present invention provides, for example, the following items. (Item 1) A helmet cover comprising a one-piece shell assembly having a receiving cavity, an inner surface, and an outer surface, the receiving cavity being configured such that the inner surface of the one-piece shell assembly is configured to contact an outer surface of a helmet, and the one-piece shell assembly fitably and removably covers the outer surface of the helmet. (Item 2) Item 1. The helmet cover of item 1, wherein the one-piece shell assembly fitably and removably covers the outer surface of the helmet without the use of adjustable fasteners. (Item 3) Item 1. The helmet cover according to item 1, wherein the helmet cover further comprises a finishing layer, the finishing layer being adhered to the outer surface of the one-piece shell assembly. (Item 4) Item 1. The helmet cover of item 1, wherein the one-piece shell assembly further comprises one or more openings therethrough, the one or more openings corresponding to one or more openings in the helmet. (Item 5) Item 1. The helmet cover of item 1, wherein the one-piece shell assembly further comprises a gripping member, the gripping member being snap-fitably attached to an outer edge of an outer surface of the protective helmet. (Item 6) Item 1. The helmet cover of item 1, wherein the one-piece shell assembly is made from injection-molded thermoplastic polyurethane (TPU) or thermoformed TPU. (Item 7) Item 1. The helmet cover according to item 1, wherein the one-piece shell assembly is made from a material selected from the group consisting of TPU90, TPU95, and mixtures thereof. (Item 8) Item 1. The helmet cover according to item 1, wherein the unitary shell assembly is made from TPU and, optionally, one or more additives selected from the group consisting of color pigments, finishing surface chemicals, utility additives, and mixtures thereof. (Item 9) Item 1. The helmet cover of item 1, wherein the inner surface of the one-piece shell assembly is provided with a plurality of microperforations. (Item 10) Item 1. The helmet cover of item 1, wherein the outer surface of the one-piece shell assembly is provided with a plurality of microperforations. (Item 11) Item 1. The helmet cover of item 1, wherein the unitary shell assembly comprises a plurality of micro-perforations, each of the plurality of micro-perforations independently having a diameter of approximately 1 μm±0.5 μm. (Item 12) The unitary shell assembly includes a plurality of microholes, the plurality of microholes having a density of about 3.2e7 microholes / cm 2 Item 1. The helmet cover according to item 1, having a distribution of (Item 13) Item 2. The helmet cover according to item 1, wherein the one-piece shell assembly has a thickness of 0.25 mm to 4 mm. (Item 14) Item 1. The helmet cover according to item 1, wherein the unitary shell assembly has a thickness of 1±0.1 mm. (Item 15) 1. A method of manufacturing a helmet cover, said method comprising: A. Providing a polymer injection unit, said polymer injection unit comprising: (i) a barrel-mounted screw assembly, the barrel-mounted screw assembly comprising a screw mounted within a barrel; (ii) a processing space, the processing space having a distal end and a proximal end; (iii) one or more nozzles in fluid communication with the processing space, the one or more nozzles being disposed at the distal end of the processing space; and B. providing an injection mold tool, the injection mold tool comprising a mold cavity in fluid communication with the one or more nozzles, the injection mold tool being constructed to form the helmet cover in a single piece; C. introducing a polymeric material into the processing space; D. melting the polymeric material in the processing space, wherein the melting is accomplished by using the screw mounted within the barrel to mix the polymeric material, applying a heat source to bring the polymeric material to a first predetermined temperature, and creating a predetermined back pressure; E. injecting a volume of the polymeric material through the one or more nozzles into the mold cavity, the volume of the polymeric material being sufficient to fill the mold cavity; F. cooling the polymeric material within the mold cavity to a second predetermined temperature; G. Extracting the polymer material in the mold cavity from the injection mold tool to provide the helmet cover; A method comprising: (Item 16) Item 16. The method of item 15, wherein the polymer material is a thermoplastic polyurethane (TPU). (Item 17) Item 16. The method of item 15, wherein the polymer material is selected from the group consisting of at least TPU90, TPU95, or a mixture thereof. (Item 18) Item 16. The method of item 15, wherein the polymeric material is TPU and, optionally, one or more additives, wherein the one or more additives are selected from the group consisting of color pigments, finishing surface chemicals, utility additives, and mixtures thereof. (Item 19) Item 16. The method according to item 15, wherein the helmet cover has a thickness of 1±0.1 mm. (Item 20) Item 16. The method of item 15, wherein the mold cavity is formed to provide micro-holes on the helmet cover. (Item 21) Item 16. The method for manufacturing the helmet cover, further comprising providing micro-holes on the helmet cover via a mechanical process or a laser drilling process after extracting the polymer material in the mold cavity from the mold. (Item 22) Item 16. The method according to item 15, wherein the mold cavity is formed to provide micropores on the helmet cover, the micropores having a diameter of about 1 μm±0.5 μm. (Item 23) Item 16. The method according to item 15, wherein the first predetermined temperature is 230±3°C. (Item 24) Item 16. The method of item 15, wherein the predetermined back pressure is 5±1 bar. (Item 25) Item 16. The method of item 15, wherein the second predetermined temperature is 60±2°C. (Item 26) Item 16. The method of item 15, wherein injecting the volume of the polymeric material is achieved by applying a first progressive pressure gradient, the progressive pressure gradient being between about 70 bar and 15 bar. (Item 27) 16. The method of claim 15, wherein injecting the volume of polymeric material occurs within 20±5 seconds. (Item 28) Item 16. The method of item 15, wherein cooling the polymeric material within the mold cavity occurs within 60±5 seconds. (Item 29) 16. The method of claim 15, wherein the steps of introducing the polymeric material into the processing space, melting the polymeric material in the processing space, injecting a volume of the polymeric material into the mold cavity through one or more nozzles, and cooling the polymeric material in the mold cavity occur within 130±20 seconds. (Item 30) 16. The method of claim 15, wherein injecting the volume of the polymer material into the mold cavity through the one or more nozzles further comprises holding the mold cavity at a holding pressure of 100 bar when the mold cavity is 99% full by volume. (Item 31) Providing injection formwork tools is scanning a helmet and obtaining a helmet geometry file; modifying the helmet geometry file to form a helmet cover geometry file; Printing a 3D helmet cover prototype; adjusting the helmet cover geometry file; generating the injection mold tool using the helmet cover geometry file; further comprising modifying the helmet geometry file includes one or more of: manipulating the size of the helmet cover; manipulating the shape of the helmet cover; modifying the structure of the helmet cover; adding one or more gripping members to the helmet cover; adding a plurality of micro-perforations to the helmet cover; or a combination thereof; Item 16. The method of item 15, wherein adjusting the helmet cover geometry file includes providing an improved fit of the helmet cover compared to a three-dimensional helmet cover prototype. [Brief explanation of the drawings]

[0014] [Figure 1] FIG. 1 is an illustration of a helmet cover positioned adjacent to a helmet according to one embodiment of the present disclosure.

[0015] [Figure 2] FIG. 2 depicts a helmet cover according to one embodiment of the present disclosure.

[0016] [Figure 3A] FIG. 3A is a perspective view of the right side of a helmet cover according to one embodiment of the present disclosure.

[0017] [Figure 3B] FIG. 3B is a perspective view of the back of a helmet cover according to one embodiment of the present disclosure.

[0018] [Figure 3C] FIG. 3C is a perspective view of the top of a helmet cover according to one embodiment of the present disclosure.

[0019] [Figure 3D] FIG. 3D is a perspective view of a front portion of a helmet cover according to one embodiment of the present disclosure.

[0020] [Figure 3E]FIG. 3E is a perspective view of the bottom of a helmet cover according to one embodiment of the present disclosure.

[0021] [Figure 4] FIG. 4 is a close-up view of an exemplary helmet cover with gripping members according to one embodiment of the present disclosure.

[0022] [Figure 5] FIG. 5 depicts a helmet cover with a finishing layer according to one embodiment of the present disclosure.

[0023] [Figure 6] FIG. 6 illustrates a method of manufacturing a helmet cover according to one embodiment of the present disclosure.

[0024] [Figure 7] FIG. 7 depicts a polymer injection unit according to one embodiment of the present disclosure.

[0025] [Figure 8] FIG. 8 depicts an injection mold tool according to one embodiment of the present disclosure.

[0026] [Figure 9] FIG. 9 illustrates a method of providing an injection mold tool according to one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0027] The present invention may be understood more readily by perusing the following detailed description of the invention and a study of the included examples.

[0028] As used herein, the following terms have the meanings ascribed to them unless specified otherwise.

[0029] As used in this specification and claims, the terms "comprise," "comprising," "include," "including," and "includes" are intended to specify the presence of stated materials, substances, features, integers, components, or steps, but they do not exclude the presence or addition of one or more other materials, substances, features, integers, components, steps, or combinations thereof.

[0030] The term "about" modifies the subject value so that they are within an acceptable error range as determined by one of ordinary skill in the art, which will depend in part on the limitations of the measurement system.

[0031] As used herein, the articles "a" and "an" refer to "one or more" or "at least one," unless otherwise indicated. That is, the reference to any element or component of an embodiment by the indefinite article "a" or "an" does not exclude the possibility that more than one of the element or component is present.

[0032] The term "helmet," as used herein, refers to a protective head covering for use in any of a variety of applications, including sports, personal protective equipment (such as in construction or manufacturing), military, or other applications. The term "helmet" is intended to include any helmet type, including, but not limited to, helmets used in American football, baseball, lacrosse, hockey, equestrian, skiing, snowboarding, construction, military applications, and the like. Suitable exemplary helmets currently on the market are provided in Example 1. It should be understood that one skilled in the art would understand that these helmets may be modified by manufacturers over time and that new helmets may enter the market. Any similar helmet or future helmet model would be included within the meaning of this term.

[0033] The term "helmet cover" as used herein refers to an article for covering a helmet. Helmet covers may be suitable for any helmet type, including, but not limited to, helmets used in American football, baseball, lacrosse, hockey, equestrian, skiing, snowboarding, construction, military applications, etc. Helmet covers may be used for any suitable purpose, including as a decorative and / or protective cover.

[0034] The term "unitary shell assembly" as used herein refers to any number of components formed integrally during a manufacturing process. As one non-limiting example, in certain embodiments, a unitary shell assembly includes a receiving cavity, an interior surface, and an exterior surface, all of which may be formed from the same thermoplastic, a blend of thermoplastics, or a blend of a thermoplastic and one or more additives. As another non-limiting example, in certain embodiments, a unitary shell assembly includes a receiving cavity, an interior surface, and an exterior surface, all of which may be formed within a single mold cavity.

[0035] The term "receiving cavity" as used herein refers to a space configured to receive an object with a predetermined geometric shape. By way of example, in certain embodiments, a receiving cavity may be configured to receive a helmet of any suitable shape and / or size.

[0036] The term "interior surface" as used herein refers to a surface that faces inwardly toward a user.

[0037] The term "exterior surface" as used herein refers to a surface that faces outwardly toward a user and includes any surface that is not an interior surface. An exterior surface may have one or more outer edges that define the outer limits of the exterior surface.

[0038] The terms "fitted" or "fittably" as used herein refer to a snug, close, or comfortable relationship between two objects. In certain embodiments, a "fitted" relationship allows the two objects to remain in contact in the absence of pulling forces, with or without the aid of fasteners or gripping members.

[0039] The terms "detach" or "detachably" as used herein refer to the ability to separate two objects. In certain embodiments, the objects may be detached through the use of a pulling force.

[0040] The term "adjustable fastener" as used herein refers to a device for closing or securing an object that can be modified or moved to achieve a desired fit or appearance. Exemplary adjustable fasteners may include, but are not limited to, buckles, straps, screws, clamps, hinges, latches, hooks, and clips.

[0041] The term "finish layer" as used herein refers to a surface layer applied to the interior or exterior surface of a helmet cover. In some embodiments, the finish layer may include paint, powder coating, graphics, thin film formulations, or combinations thereof. In some embodiments, the finish layer may be applied by painting, bead blasting, etching, UV curing, silk screening, hydro-dipping, physical vapor deposition, or combinations thereof.

[0042] The terms "adhere," "adheres," or "adhered," as used herein, refer to joining or creating contact between two or more surfaces or materials through molecular interactions.

[0043] The term "gripping member" as used herein refers to a component used to grip or hold the outer edge of the outer surface.

[0044] The term "snappably attaches" as used herein refers to closing or fitting components into place without adjustment through a sudden force.

[0045] The term "thermoplastic" as used herein refers to a class of polymers that become pliable or moldable at certain elevated temperatures and solidify upon cooling. Exemplary thermoplastics include, but are not limited to, polyurethane ("TPU"), polypropylene ("PP"), polyethylene ("PE"), polystyrene ("PS"), polyvinyl chloride ("PVC"), poly(methyl methacrylate) ("PMMA"), polycarbonate ("PC"), polyoxymethylene ("POM"), polyethylene vinyl acetate ("PEVA"), high-density polyethylene ("HDPE"), acrylonitrile butadiene styrene ("ABS"), polyamide ("PA nylon"), or mixtures thereof. Different thermoplastics or mixtures of thermoplastics can be used depending on the application, including the desired physical attributes of the finished product. In some embodiments, the thermoplastic can be recycled thermoplastic from waste products, discarded products, or other uses.

[0046] The term "polymeric material" as used herein refers to an injection molded substrate, which may include one or more thermoplastics and, optionally, additional additives such as color pigments, glitter, finishing surface chemicals, utility additives, and mixtures thereof.

[0047] The term "thermoplastic polyurethane ("TPU")" as used herein refers to a type of thermoplastic plastic made from block copolymers consisting of alternating sequences of hard (high polarity) and soft (low polarity) domains formed by the reaction of diisocyanates with short-chain diols and diisocyanates with long-chain diols. TPUs are generally characterized by high durability, flexibility, and tensile strength.

[0048] TPUs are available in several hardness grades, measured by the TPU's Shore A and / or Shore D values, which are determined according to ASTM D2240. TPUs with hardness values ​​of approximately 10A to 50A are very soft, TPUs with hardness values ​​of 50A to 80A are soft, TPUs with hardness values ​​of 80A to 90A are medium, TPUs with hardness values ​​of 90 to 95A are hard, and TPUs with hardness values ​​of 60D to 75D are very hard. The term "TPU90" refers to a TPU with a Shore A value of 90. The term "TPU95" refers to a TPU with a Shore A value of 95.

[0049] Other defining properties of a TPU or blend of TPUs include density (e.g., as measured by ASTM D792), tensile strength and elongation at break (e.g., as measured by ASTM D412), abrasion (e.g., as measured by ISO 4649), and tear strength (e.g., as measured by ASTM D624). The most suitable TPU or blend of TPUs for a particular product will depend on the application, manufacturing method, and desired physical attributes of the finished product.

[0050] The term "additive" refers to any substance added to a thermoplastic or a mixture of thermoplastics to improve, modify, or preserve the attributes of a given manufactured product. In embodiments of the present invention, any number of suitable additives may be used alone or in combination, provided that the additives achieve their intended purpose and do not adversely affect the performance characteristics of the helmet cover to an appreciable extent. Exemplary additives include, but are not limited to, color pigments, finish surface chemicals, utility additives, and mixtures thereof. When present, additives may be employed in any suitable amount, provided that the additives achieve their intended purpose and do not adversely affect the performance characteristics of the helmet cover to an appreciable extent.

[0051] The term "thickness" as used herein refers to the distance between opposing surfaces. For example, in certain embodiments, the term "thickness" refers to the distance between the inner surface of a helmet cover and the outer surface of the helmet cover. While various thicknesses are disclosed, it is understood that the process for manufacturing the articles is subject to natural process variations, and therefore, reasonable deviations from the desired thickness are within the scope of this disclosure. For example, regardless of whether the unitary shell assembly described herein has a single or multiple thicknesses, each of the one or more thicknesses will typically be between 0.25 mm and 4 mm.

[0052] The term "up to" as used herein refers to values ​​less than the indicated value and greater than zero (i.e., will not include the value zero (0)). For example, in reference to a unitary shell assembly described herein having a thickness of up to 4 mm, the thickness will be less than 4 mm and greater than zero.

[0053] The terms "injection molding" or "injection molded" as used herein refer to a manufacturing process for producing an article by injecting molten material into an injection mold tool. The material for the article, such as a thermoplastic or a blend of thermoplastics, is fed into a polymer injection unit, melted, and injected into the mold cavity through a nozzle in fluid communication with both the polymer injection unit and the mold cavity, where it is then cooled to assume the shape of the mold cavity.

[0054] The term "polymeric injection unit" as used herein refers to a unit operating for melting polymeric material during injection molding. While various configurations are known in the art, the unit generally includes a barrel-mounted screw assembly, a processing space, and one or more nozzles in fluid communication with the processing space. The polymeric injection unit may also include a hopper assembly for introducing the polymeric material into the processing space. In certain embodiments, the hopper assembly includes a conical hopper, a hopper block positioned within the processing space to support the conical hopper, and optionally, a hopper heater and dryer for adjusting the moisture content of the polymeric material prior to delivery. The polymeric injection unit may additionally include vents or ports for reducing the volatile moisture content of the water and / or polymeric material.

[0055] The term "barrel-mounted screw assembly" as used herein refers to a cylinder with a helical channel that is mounted within the processing space of a polymer injection unit.

[0056] The term "processing space" as used herein refers to the hollow chamber within the polymer injection unit in which the barrel-mounted screw assembly operates.

[0057] The term "nozzle" as used herein refers to a tubular section used to inject polymeric material into an injection mold tool.

[0058] The term "injection mold tool" as used herein refers to an assembly of parts that allows molten polymeric material to be formed and cooled to produce a discrete manufactured article, such as a helmet cover. The injection mold tool includes a mold cavity.

[0059] The term "mold cavity" as used herein refers to the portion of an injection mold tool that, upon cooling, imparts the shape of the manufactured article to the molten polymeric material. The mold cavity includes a hollow portion and a core portion, which together provide the shape of the manufactured article. In the production of helmet covers, the hollow portion of the mold cavity provides the shape of the outer surface of the helmet cover, while the core portion provides the shape of the inner surface of the helmet cover.

[0060] The term "in communication with," as used herein, refers to the ability to move between two or more units or manufacturing steps. By way of example, when one unit or manufacturing step is "in fluid communication" with another unit or manufacturing step, it means that a fluid (such as a molten polymeric material) can move between the two units.

[0061] The term "predefined" as used herein refers to a set point that is established in advance. For example, the term "predefined temperature" refers to a desired temperature set point. As another example, the term "predefined pressure" refers to a desired pressure set point. A predetermined set point may be determined based on manufacturing process specifications, such as the melting point of a polymeric material. While various predetermined set points are disclosed, it is understood that processes for manufacturing articles are subject to set point variations and, therefore, reasonable deviations from desired predetermined values ​​are within the scope of the present disclosure.

[0062] The term "progressive gradient" as used herein refers to a series of predetermined variables that vary in steps. For example, the term "progressive pressure gradient" refers to a series of predetermined pressures that are achieved in sequence. While various predetermined set points for the progressive gradient are disclosed, it is understood that the process for manufacturing the article is subject to variation in the set points, and therefore, reasonable deviations from the desired progressive gradient are within the scope of this disclosure.

[0063] The term "backpressure" as used herein refers to the amount of pressure that the polymeric material exerts on the barrel-mounted screw assembly during melting.

[0064] The term "holding pressure," as used herein, refers to the amount of pressure applied during the final stage of filling the mold cavity. In some embodiments, holding pressure is applied when the mold cavity is about 90-99% filled by volume. In some embodiments, holding pressure is applied when the mold cavity is about 95-99% filled by volume. In some embodiments, holding pressure is applied when the mold cavity is about 99% filled by volume.

[0065] The term "injecting" as used herein refers to the process of forcing molten polymeric material through one or more nozzles into a mold cavity of an injection molding tool.

[0066] The term "cooling" as used herein refers to the process of solidifying molten polymeric material within the mold cavity of the injection molding tool.

[0067] The term "extracting" as used herein refers to the process of removing cooled polymeric material from within the mold cavity of an injection mold tool to provide a desired manufactured article, such as a helmet cover. Extraction can be performed manually, robotically, or using specialized tools.

[0068] The term "helmet geometry file" refers to a computerized model, such as a CAD representation, taken of a helmet.

[0069] The term "helmet cover geometry file" refers to a modified helmet geometry file.

[0070] The term "3-dimensional helmet cover prototype" refers to a physical representation of a helmet cover geometric shape file obtained by 3-dimensional printing.

[0071] The term "altering" refers to changing the structure, design, and / or dimensions of an object.

[0072] The term "adjusting" refers to a slight manipulation that improves the fit and / or appearance of an object.

[0073] 1, a helmet cover 100 and a helmet 102 are illustrated. The helmet 102 includes one or more helmet openings 104 and one or more helmet fastening locations 106. The helmet cover 100 is designed to have a shape that closely resembles the shape of the helmet 102 and includes any helmet openings 104 and helmet fastening locations 106. For example, as shown in FIGS. 1-2, the helmet cover 100 includes one or more openings 108 that correspond to the helmet openings 104. Similarly, the helmet cover 100 includes one or more openings 108 that correspond to the helmet fastening locations 106.

[0074] 1-2 , the helmet cover 100 is sized to slide over the outer surface of the helmet 102 so as to conformably cover the outer surface of the helmet 102. While the helmet cover 100 may be removed from the helmet 102, the fit between the helmet cover 100 and the helmet 102 is such that the helmet cover 102 will not be removed from the helmet 100 without the application of a pulling force. Because the helmet cover 100 is formed to conformably cover the outer surface of the helmet 102, adjustable fasteners are not required to achieve a desired fit between the helmet cover 100 and the helmet 102.

[0075] 3A-E, the helmet cover 100 of the present invention includes a one-piece shell assembly 202. The one-piece shell assembly 202 includes an inner surface 204, an outer surface 206, and a receiving cavity 208. The receiving cavity 208 has a shape and size that closely resembles the shape and size of the outer surface of the helmet 102.

[0076] The helmet cover 100 can be made from a thermoplastic, a blend of thermoplastics, or one or more thermoplastics and one or more additives. Exemplary thermoplastics include polyurethane ("TPU"), polypropylene ("PP"), polyethylene ("PE"), polystyrene ("PS"), polyvinyl chloride ("PVC"), poly(methyl methacrylate) ("PMMA"), polycarbonate ("PC"), polyoxymethylene ("POM"), polyethylene vinyl acetate ("PEVA"), high-density polyethylene ("HDPE"), acrylonitrile butadiene styrene ("ABS"), polyamide ("PA nylon"), or a blend thereof. For example, the helmet cover 100 can be made from one or more TPUs. Exemplary additives include, but are not limited to, color pigments, finishing surface chemicals, utility additives, and a blend thereof. In one embodiment, the helmet cover 100 is made from TPU90, TPU95, or a blend thereof.

[0077] 4, in one embodiment, the unitary shell assembly 202 of the helmet cover 100 further includes a gripping member 300. The gripping member 300 is formed to provide a clip 304 sized to accommodate the outer edge of the outer surface of the helmet 102. The gripping member 300 is designed so that it can be snap-fitted onto the outer edge of the outer surface of the helmet 102, thus providing a secure and partially enveloping fit with the outer edge. The gripping member 300 can be designed to accommodate the entire outer edge of the outer surface of the helmet 102, or it can be designed to accommodate only a certain outer edge of the outer surface of the helmet 102, with the outer edge being selected according to the desired appearance of the helmet cover 100.

[0078] As shown in FIG. 5, the helmet cover 100 may further include a finish layer 400. It is understood that one skilled in the art would recognize any number of suitable finish layers, and that any such finish layer may be used as long as it withstands the applied forces and intended use. For example, the finish layer 400 may include one or more of a paint, a powder coating, a protective coating, a graphic, a thin film formulation, or a combination thereof. The finish layer 400 may be applied by painting, bead blasting, etching, UV curing, silk screening, hydro-dipping, physical vapor deposition, or other known application techniques.

[0079] The inner surface 204 and / or the outer surface 206 of the helmet cover 100 may include a plurality of microperforations. When applied to the inner surface 204 and / or the outer surface 206, the plurality of microperforations may improve the surface properties of the inner surface 204 and / or the outer surface 206. For example, the microperforations may modify the coefficient of friction experienced by the inner surface 204 and / or the outer surface 206, or may modify the porosity of the inner surface 204 and / or the outer surface 206 and promote adhesion of the finishing layer 400. The microperforations may be imparted on the inner surface 204 and / or the outer surface 206 as part of the injection molding process or by a mechanical or laser process after injection molding is completed. The diameter, density, and location of the microperforations may be varied to achieve desired surface properties.

[0080] The helmet cover 100 of the present invention may generally be manufactured according to known methods for manufacturing articles made from thermoplastics, such as injection molding, thermoforming, and the like.

[0081] For example, the helmet cover 100 may be manufactured via an injection molding process. As shown in Figure 6, the injection molding method 600 includes (602) introducing a polymeric material, (604) melting the polymeric material, (606) injecting the polymeric material, (608) cooling the polymeric material, (610) extracting the polymeric material, and (612) providing a helmet cover.

[0082] 7, in one embodiment, step 602: introducing polymer material is accomplished by feeding polymer material 710 into a polymer injection unit 700. In one embodiment, the polymer injection unit 700 includes a processing space 704, a barrel-mounted screw assembly 702, and one or more nozzles 706 in fluid communication with both the processing space 704 and an injection mold tool 800. The polymer injection unit may optionally include a hopper assembly 708 for introducing the polymer material 710 into the processing space 704. The hopper assembly 708 may optionally include a conical hopper, a hopper block disposed within the processing space to support the conical hopper, and optionally a hopper heater and dryer for adjusting the moisture content of the polymer material prior to feeding. The polymer injection unit 700 may also optionally include vents or ports for reducing the water and / or volatile moisture content of the polymer material 710.

[0083] Step 602: During the introduction of the polymer material, the barrel-mounted screw assembly 702 rotates within the processing space 704, transporting the polymer material 710 in a proximal-to-distal direction through the processing space, whereby the interaction between the barrel-mounted screw assembly and the processing space generally produces axial (i.e., forward) movement of the polymer material.

[0084] 6 and 7 , during step 604, i.e., melting the polymeric material, the barrel-mounted screw assembly 702 and the outer limit of the processing space 704 (commonly referred to as the barrel) interact to melt, convey, and apply pressure to the polymeric material 710, preparing the polymeric material for step 606: injecting the polymeric material. To facilitate this interaction, the barrel of the processing space 704 may be partially or fully grooved, depending on the application. Similarly, the length, diameter, and rotational speed of the barrel-mounted screw assembly 702 can be varied to obtain desired melting characteristics and consistent output. In certain embodiments, the barrel-mounted screw assembly 702 may include one or more sections in which the screw diameter or helical channel pitch can be varied to provide the appropriate feed rate, compression, and metering. The melt uniformity of the polymeric material 710 can also be varied by predefining the force generated by the barrel-mounted screw 702, also referred to as backpressure.

[0085] The processing space 704 may additionally have one or more barrel sections 712, each with its own temperature set point for bringing the polymeric material 710 to a first predetermined temperature for step 604: melting the polymeric material. The first predetermined temperature may be a specific temperature set point or may be a temperature gradient. It should be understood that the temperature set point for each of the one or more barrel sections 712 may be varied according to the processing specifications of the polymeric material 710.

[0086] When more than one barrel section 712 is included within the processing space, the barrel section 712 on the proximal end (712a) of the processing space generally has the lowest temperature set point to prevent premature melting and crosslinking during step 602: introducing the polymeric material. The temperatures of the remaining barrel sections 712 can then be varied in a direction progressing from the proximal end to the distal end of the processing space, for example, by increasing the barrel section temperature set point in the distal direction. In this manner, the temperature set points increase as one moves from 712a, 712b, 712c, and 712d. For example, in one embodiment, the temperature set points can be 200±5°C for barrel section 712a, 215±5°C for barrel section 712b, 225±5°C for barrel section 712c, and 230±5°C for barrel section 712d.

[0087] 6 and 7, during step 606: injecting polymer material, polymer material 710 is forced through one or more nozzles 706 and introduced into injection mold tool 800. As shown in FIG. 8, in one embodiment, injection mold tool 800 includes a positioning ring 802, a sprue bushing 804, a spacer plate 806, guide columns 808 and guide bushings 810, a runner 824, a mold cavity 812, a stationary plate 818, a movable plate 820, a core holding plate 822, an ejector pin 826, an ejector plate 828, and a clamp plate 830. Mold cavity 812 includes one or more cavity portions 814 and a core portion 816.

[0088] 6-8 , when performing the injection molding method 600, the one or more nozzles 706, sprue bushing 804, and runner 824 are in communication so that the polymer material 710 can be forced from the processing space 704 into and fill the mold cavity 812. In one embodiment, during step 606: injecting the polymer material, the mold cavity 812 is filled in two phases, referred to as a filling / packing phase and a holding phase.

[0089] During the filling / packing stage, the molten polymer material 710 is injected under a first progressive pressure gradient that is applied to fill the mold and then allow for contraction and backflow of the molten polymer material 710. In one embodiment, the progressive pressure gradient is between about 70 bar and 15 bar.

[0090] During the holding stage, the molten polymeric material 710 is held at a particular holding pressure until no additional polymeric material 710 flows into the mold cavity 812. The holding pressure can be varied depending on the processing specifications of the polymeric material 710 and can be a pressure gradient. The holding pressure is applied when the mold cavity 812 is approximately 90-99% filled by volume.

[0091] 6 , during step 608: cooling the polymeric material, the polymeric material 710 in the mold cavity 812 is cooled to a second predetermined temperature. It should be understood that the second predetermined temperature may be varied according to the processing specifications of the polymeric material 710. The second predetermined temperature may be achieved by cooling the cavity portion 814 and the core portion 816 to a particular temperature set point. The temperature set points for the cavity portion 814 and the core portion 816 may be the same or different depending on the process. For example, the temperature set points for the cavity portion 814 and the core portion 816 may be within a range of 60° C.±10° C.

[0092] 6, during step 610: extracting the polymer material, the helmet cover 100 is removed from the mold cavity 812 and the injection mold tool 800. Step 610: extracting the polymer material can be accomplished by use of an ejector pin 826 and an ejector plate 828, by manual extraction, or both. Finally, during step 612, i.e., providing a helmet cover, the helmet cover 100 is provided according to embodiments described herein.

[0093] 9, the injection mold tool 800 can be designed and provided via a method for providing a tool 900. In one embodiment, the method for providing the tool 900 includes (902) scanning the helmet 102 to obtain a helmet geometry file, (904) modifying the helmet geometry file to form a helmet cover geometry file, (906) printing a three-dimensional helmet cover prototype from the helmet cover geometry file, (908) adjusting the helmet cover geometry file, and (910) generating the injection mold tool 800 using the helmet cover geometry file.

[0094] During step 902, i.e., scanning the helmet 102 to obtain a helmet geometry file, the helmet 102 is scanned to generate a computerized model of the helmet 102. In one embodiment, the computerized model may be a CAD STEP file. For example, the helmet geometry file may be generated by scanning the helmet 102, obtaining associated surface measurements, and generating a CAD model using known methods of surface measurement and surface data output. These methods include generating a point cloud or mesh data output. Point cloud data is provided by applying pulses of laser light to the surface of an object, measuring the amount of time it takes each pulse to reflect back to the scanner, and using the time measurements to determine the precise location of points on the scanned object. Mesh data is obtained by subdividing the surface structure into a set of polygons, which divide the continuous surface into vertices, edges, and faces, which may be represented in the computerized model.

[0095] Step 904: Modify the helmet geometry file to form a helmet cover geometry file. During this step, the helmet geometry file is manipulated to generate a helmet cover geometry file. The modifications may include manipulating the size, shape, and / or structure of the helmet 102 depicted in the geometry file. The modifications may include manipulating the thickness of the helmet geometry file, adding one or more openings to the helmet geometry file, adding one or more gripping members to the helmet geometry file, adding microperforations to the helmet geometry file, or a combination thereof. The file resulting from the modifications applied to the helmet geometry file is referred to as a helmet cover geometry file.

[0096] For example, during step 904: modifying the helmet geometry file to form the helmet cover geometry file, the helmet geometry file may be modified by manipulating the size and shape of the helmet 102 depicted in the helmet geometry file to obtain the helmet cover geometry file. To manipulate the size, the helmet geometry file is expanded in all directions by an amount equivalent to the desired thickness of the helmet cover 100. To manipulate the shape, the expanded helmet geometry file is then modified to skive the inner surface depicted in the helmet geometry file, thereby causing the final product to have a total thickness equivalent to the desired thickness of the helmet cover 100. Manipulating the size and shape of the helmet geometry file in this manner to generate the helmet cover geometry file allows the finished helmet cover 100 to slide over the helmet 102 rather than "stacking" on top of the helmet 102. Certain types of size and shape manipulations also preserve the helmet-like shape of the helmet cover 100, which ensures that the helmet cover 100 fits snugly over the helmet 102 despite the large and irregular shapes of both the helmet cover 102 and the helmet 100. Additional modifications can then be made to the helmet geometry file, such as adding one or more openings to the helmet geometry file, adding one or more gripping members to the helmet geometry file, adding micro-perforations to the helmet geometry file, or combinations thereof. The final product of the modifications is a helmet cover geometry file.

[0097] During step 906, i.e., printing a three-dimensional helmet cover prototype from the helmet cover geometry file, a three-dimensional helmet cover prototype corresponding to the helmet cover geometry file is provided. The three-dimensional helmet cover prototype allows the manufacturer to inspect the fit of the three-dimensional helmet cover prototype when it is applied to the helmet 102 and note any areas requiring adjustment. During step 908: adjusting the helmet cover geometry file, the helmet cover geometry file is adjusted to provide an improved fit of the helmet cover 100 compared to the three-dimensional helmet cover prototype. Step 906: printing a three-dimensional helmet cover prototype from the helmet cover geometry file and step 908: adjusting the helmet cover geometry file can be repeated as many times as necessary to achieve the desired fit and design of the helmet cover 100 when it is applied to the helmet 102.

[0098] Once the desired fit and design of the helmet cover geometry file is achieved, step 910: generating an injection mold tool 800 using the helmet cover geometry file is performed. The injection mold tool 800 is designed to provide the desired helmet cover 100 while also accommodating required process attributes such as injection flow rate, molded article removal, temperature and pressure control, etc. The injection mold tool is designed according to the instructions set forth herein.

[0099] (Embodiment) (Helmet cover) Aspects of the present invention relate to a helmet cover made from a one-piece shell assembly including a receiving cavity, an inner surface, and an outer surface, the receiving cavity configured such that the inner surface of the one-piece shell assembly is configured to contact the outer surface of the helmet, and the one-piece shell assembly conformably and removably covers the outer surface of the helmet.

[0100] Another aspect of the present invention relates to a helmet cover including a one-piece shell assembly. The one-piece shell assembly includes a receiving cavity, an inner surface, an outer surface, and a gripping member. The receiving cavity is configured such that the inner surface of the one-piece shell assembly is configured to contact the outer surface of the helmet. The one-piece shell assembly conformably and removably covers the outer surface of the helmet and is snap-fitably attached to the outer edge of the outer surface of the helmet through the use of the gripping member.

[0101] The specific embodiments describing components, materials, ranges, values, and steps provided below are for illustrative purposes only and do not otherwise limit the scope of the disclosed subject matter as defined by the claims.

[0102] In various embodiments, the one-piece shell assembly conformably and removably covers the outer surface of the helmet without the use of adjustable fasteners.

[0103] In various embodiments, the helmet cover also includes a finish layer adhered to the outer surface of the one-piece shell assembly. The finish layer includes any suitable finish or mixture of finishes, provided that the finish does not interfere with the desired attributes of the helmet cover, such as fit, ability to apply the finish, durability of the finish, or manufacturing method. In some embodiments, the finish layer includes paint, powder coating, graphics, thin film formulations, or combinations thereof. The finish layer can be applied by painting, bead blasting, etching, UV curing, silk screening, hydro-dipping, physical vapor deposition, or combinations thereof.

[0104] In various embodiments, the one-piece shell assembly further includes one or more openings therethrough. The one or more openings may correspond to one or more openings in the helmet. In certain embodiments, the one or more openings provide access to various helmet features.

[0105] In various embodiments, the unitary shell assembly further includes a gripping member. In certain embodiments, the gripping member is snap-fitably attached to the outer edge of the helmet's outer surface, thus providing a secure and partially enveloping fit with the outer edge. The gripping member is formed to provide a lip sized to accommodate the outer edge of the helmet's outer surface. The gripping member can be designed to accommodate the entire outer edge of the helmet's outer surface, or only a certain outer edge of the helmet's outer surface, the outer edge being selected according to the desired appearance and fit of the helmet cover.

[0106] In various embodiments, the unitary shell assembly is made from a thermoplastic. In some embodiments, the thermoplastic is formed via injection molding or thermoforming. In some embodiments, the thermoplastic is polyurethane ("TPU"), polypropylene ("PP"), polyethylene ("PE"), polystyrene ("PS"), polyvinyl chloride ("PVC"), poly(methyl methacrylate) ("PMMA"), polycarbonate ("PC"), polyoxymethylene ("POM"), polyethylene vinyl acetate ("PEVA"), high density polyethylene ("HDPE"), acrylonitrile butadiene styrene ("ABS"), polyamide ("PA nylon"), or a mixture thereof. For example, the unitary shell assembly can be made from one or more TPUs. In some embodiments, the TPU is TPU90, TPU95, or a mixture thereof.

[0107] In various embodiments, the unitary shell assembly is made from a thermoplastic and one or more additives. The one or more additives can include any suitable additive or mixture of additives, provided the additive does not interfere with the desired attributes of the helmet cover, such as fit, ability to apply a finish, durability of the finish, or manufacturing method. In some embodiments, the one or more additives can include color pigments, glitter, finishing surface chemicals, utility additives, and mixtures thereof. In some embodiments, the utility additive can include graphite, micro vacuum spheres, or mixtures thereof.

[0108] In specific embodiments, the inner surface of the unitary shell assembly and / or the outer surface of the unitary shell assembly include a plurality of micropores. The plurality of micropores are positioned and sized to facilitate insertion of a protective helmet. For example, in certain embodiments, the plurality of micropores are positioned and sized to facilitate adhesion of a finish layer present on the outer surface of the unitary shell assembly. The plurality of micropores may cover all or a portion of the inner surface of the unitary shell assembly and / or the outer surface of the unitary shell assembly. In certain embodiments, the plurality of micropores preferably each independently have a diameter of 0.1 μm to 10 μm. In certain embodiments, the plurality of micropores preferably each independently have a diameter of 0.5 μm to 5 μm. In certain embodiments, the plurality of micropores preferably each independently have a diameter of about 1 μm ± 0.5 μm. In certain embodiments, the plurality of micropores preferably each independently have a diameter of 3.2e9 to 3.2e5 micropores / cm. 2 In one embodiment, the plurality of micropores has a distribution of 1.3e8 to 1.3e6 micropores / cm 2 In one embodiment, the plurality of micropores has a distribution of about 3.2e7 micropores / cm 2 It has a distribution of

[0109] As a manufactured product, the unitary shell assembly of the helmet cover will have a particular thickness. Within the unitary shell assembly, the thickness may vary from section to section, or it may be consistent throughout. Whether the unitary shell assembly is single-thickness or multiple-thickness, each of the one or more thicknesses may be between 0.25 mm and 4 mm. For example, each of the one or more thicknesses may be up to 4 mm. Specifically, each of the one or more thicknesses may be up to 3 mm. More specifically, each of the one or more thicknesses may be up to 2 mm. More specifically, each of the one or more thicknesses may be up to 1.75 mm. More specifically, each of the one or more thicknesses may be up to 1.5 mm. Even more specifically, each of the one or more thicknesses may be up to 1.25 mm.

[0110] Similarly, each of the one or more thicknesses may be greater than 0.25 mm. For example, each of the one or more thicknesses may be greater than 0.5 mm. Specifically, each of the one or more thicknesses may be greater than 0.75 mm. More specifically, each of the one or more thicknesses may be greater than 1 mm.

[0111] In some embodiments, the unitary shell assembly has a thickness of 1 mm ± 0.75 mm. In some embodiments, the unitary shell assembly has a thickness of 1 mm ± 0.5 mm. In some embodiments, the unitary shell assembly has a thickness of 1 mm ± 0.25 mm. In some embodiments, the unitary shell assembly has a thickness of 1 mm ± 0.2 mm. In some embodiments, the unitary shell assembly has a thickness of 1 mm ± 0.15 mm. In some embodiments, the unitary shell assembly has a thickness of 1 mm ± 0.1 mm. In some embodiments, the unitary shell assembly has a thickness of 1 mm ± 0.09 mm. In some embodiments, the unitary shell assembly has a thickness of 1 mm ± 0.08 mm. In some embodiments, the unitary shell assembly has a thickness of 1 mm ± 0.07 mm. In some embodiments, the unitary shell assembly has a thickness of 1 mm ± 0.06 mm. In some embodiments, the unitary shell assembly has a thickness of 1 mm ± 0.05 mm. In some embodiments, the unitary shell assembly has a thickness of 1 mm ± 0.04 mm. In some embodiments, the unitary shell assembly has a thickness of 1 mm ± 0.03 mm. In some embodiments, the unitary shell assembly has a thickness of 1 mm ± 0.02 mm. In some embodiments, the unitary shell assembly has a thickness of 1 mm ± 0.01 mm. In some embodiments, the unitary shell assembly has a thickness of about 1 mm.

[0112] (Method for manufacturing a helmet cover) Another aspect of the present invention is a method for manufacturing a helmet cover, the method including providing a polymer injection unit within a processing space, providing an injection molding tool having a mold cavity, introducing a polymer material into the processing space, melting the polymer material within the processing space, injecting a volume of the polymer material into the mold cavity of the injection molding tool, cooling the polymer material within the mold cavity of the injection molding tool, and extracting the polymer material from the injection mold tool of the injection molding tool to provide the helmet cover.

[0113] Another aspect of the invention is a method of manufacturing a helmet cover, the method including providing a polymer injection unit, providing an injection mold tool, introducing a polymer material into a treatment space, melting the polymer material in the treatment space, injecting a volume of the polymer material, cooling the polymer material, and extracting the polymer material to provide a helmet cover.

[0114] The polymer injection unit includes a barrel-mounted screw assembly, a processing space with a distal end and a proximal end, and one or more nozzles in fluid communication with the processing space located at the distal end of the processing space. The polymer material is melted in the processing space by using the screw mounted in the barrel to mix the polymer material, applying a heat source to bring the polymer material to a first predetermined temperature, and creating a predetermined back pressure. Once melted, the polymer material is injected into an injection mold tool through the one or more nozzles.

[0115] The injection mold tool includes a mold cavity in fluid communication with one or more nozzles and is configured to form the helmet cover in one piece. When the polymer material is injected, it is injected in an amount sufficient to fill the mold cavity. The polymer material is then cooled within the mold cavity to a second predetermined temperature. Upon cooling, the polymer material is extracted from the mold cavity to provide the helmet cover.

[0116] Another aspect of the present invention is a method for providing an injection molding tool. To provide the injection molding tool, a helmet is scanned to obtain a helmet geometry file. The helmet geometry file is modified to form a helmet cover geometry file. Modifying the helmet geometry file may include one or more of manipulating the size of the helmet cover, modifying the structure of the helmet cover, adding one or more gripping members to the helmet cover, and / or adding a plurality of micro-perforations to the helmet cover. Using the helmet cover geometry file, a helmet cover prototype is generated via three-dimensional printing. Based on the fit of the helmet cover prototype, the helmet cover geometry file is adjusted to provide an improved fit of the helmet cover compared to the three-dimensional helmet cover prototype. The prototyping and adjusting are repeated until a desired fit and design for the helmet cover is achieved, and then an injection molding tool is generated using the helmet cover geometry file.

[0117] The specific embodiments describing components, materials, ranges, values, and steps provided below are for illustrative purposes only and do not otherwise limit the scope of the disclosed subject matter, as defined by the claims.

[0118] In various embodiments, the polymeric material comprises a thermoplastic. In some embodiments, the polymeric material comprises a thermoplastic, such as polyurethane ("TPU"), polypropylene ("PP"), polyethylene ("PE"), polystyrene ("PS"), polyvinyl chloride ("PVC"), poly(methyl methacrylate) ("PMMA"), polycarbonate ("PC"), polyoxymethylene ("POM"), polyethylene vinyl acetate ("PEVA"), high density polyethylene ("HDPE"), acrylonitrile butadiene styrene ("ABS"), polyamide ("PA nylon"), or a mixture thereof. For example, the polymeric material can comprise one or more TPUs. In some embodiments, the TPU is TPU90, TPU95, or a mixture thereof.

[0119] In various embodiments, the polymeric material includes a thermoplastic and one or more additives. The one or more additives can include any suitable additive or mixture of additives, provided that the additive does not interfere with the desired attributes of the helmet cover, such as fit, ability to apply a finish, durability of the finish, or manufacturing method. In some embodiments, the one or more additives can include color pigments, glitter, finishing surface chemicals, utility additives, and mixtures thereof. In some embodiments, the utility additive can include graphite, micro vacuum spheres, or mixtures thereof.

[0120] In various embodiments, the method for manufacturing a helmet cover further includes providing micro-apertures on the helmet cover. In some embodiments, the mold cavity is formed to provide micro-apertures on the helmet cover. In some embodiments, providing micro-apertures on the helmet cover is achieved via a mechanical process or a laser drilling process after extracting the polymeric material from the mold cavity. The micro-apertures are positioned and sized to facilitate insertion of a protective helmet. For example, in some embodiments, the micro-apertures are positioned and sized to facilitate adhesion of a finish layer present on the outer surface of the unitary shell assembly. The micro-apertures may cover all or a portion of the inner surface of the unitary shell assembly and / or the outer surface of the unitary shell assembly. In some embodiments, the method for manufacturing a helmet cover further includes providing micro-apertures having a diameter of 0.1 μm to 10 μm. In some embodiments, the method for manufacturing a helmet cover further includes providing micro-apertures having a diameter of 0.5 μm to 5 μm. In some embodiments, the method for manufacturing a helmet cover further includes providing micro-apertures having a diameter of 1 μm to ±0.5 μm. In one embodiment, the method for manufacturing the helmet cover comprises the step of: 2 In one embodiment, the method for manufacturing a helmet cover further comprises providing micropores having a distribution of 1.3e8 to 1.3e6 micropores / cm. 2 In one embodiment, the method for making a helmet cover further comprises providing micropores having a distribution of about 3.2e7 micropores / cm 2 In various embodiments, the micropores may cover all or a portion of the inner surface of the unitary shell assembly, the outer surface of the unitary shell assembly, or both.

[0121] In various embodiments, a method for manufacturing a helmet cover includes melting a polymeric material in a processing space by bringing the material to a first predetermined temperature. In some embodiments, the first predetermined temperature is 230±30°C. In some embodiments, the first predetermined temperature is 230±20°C. In some embodiments, the first predetermined temperature is 230±15°C. In some embodiments, the first predetermined temperature is 230±10°C. In some embodiments, the first predetermined temperature is 230±5°C. In some embodiments, the first predetermined temperature is 230±3°C.

[0122] In various embodiments, a method for manufacturing a helmet cover includes creating a predetermined backpressure while melting a polymeric material in a processing space. In some embodiments, the predetermined backpressure is less than about 20 bar. In some embodiments, the predetermined backpressure is less than about 15 bar. In some embodiments, the predetermined backpressure is less than about 10 bar. In some embodiments, the predetermined backpressure is 5±1 bar.

[0123] In various embodiments, the method of manufacturing a helmet cover includes cooling the polymeric material in the mold cavity to a second predetermined temperature. In some embodiments, the second predetermined temperature is 60±10°C. In some embodiments, the second predetermined temperature is 60±8°C. In some embodiments, the second predetermined temperature is 60±6°C. In some embodiments, the second predetermined temperature is 60±4°C. In some embodiments, the second predetermined temperature is 60±2°C.

[0124] In various embodiments, a method for manufacturing a helmet cover includes injecting a volume of polymeric material, which is achieved by applying a first progressive pressure gradient. In some embodiments, the progressive pressure gradient is from about 80 bar to about 10 bar. In some embodiments, the progressive pressure gradient is from about 70 bar to about 15 bar.

[0125] In various embodiments, injecting the volume of polymeric material occurs within 20±20 seconds. In some embodiments, injecting the volume of polymeric material occurs within 20±15 seconds. In some embodiments, injecting the volume of polymeric material occurs within 20±10 seconds. In some embodiments, injecting the volume of polymeric material occurs within 20±5 seconds.

[0126] In various embodiments, cooling of the polymeric material within the mold cavity occurs within 60±20 seconds. In some embodiments, cooling of the polymeric material within the mold cavity occurs within 60±15 seconds. In some embodiments, cooling of the polymeric material within the mold cavity occurs within 60±10 seconds. In some embodiments, cooling of the polymeric material within the mold cavity occurs within 60±5 seconds.

[0127] In various embodiments, introducing the polymeric material into the processing space, melting the polymeric material in the processing space, injecting a volume of the polymeric material into the mold cavity through one or more nozzles, and cooling the polymeric material in the mold cavity occur within 130±40 seconds. In some embodiments, melting the polymeric material in the processing space, injecting a volume of the polymeric material into the mold cavity through one or more nozzles, and cooling the polymeric material in the mold cavity occur within 130±30 seconds. In some embodiments, melting the polymeric material in the processing space, injecting a volume of the polymeric material into the mold cavity through one or more nozzles, and cooling the polymeric material in the mold cavity occur within 130±20 seconds. In some embodiments, melting the polymeric material in the processing space, injecting a volume of the polymeric material into the mold cavity through one or more nozzles, and cooling the polymeric material in the mold cavity occur within 130±10 seconds.

[0128] In various embodiments, injecting a volume of polymeric material into the mold cavity through one or more nozzles further includes holding the mold cavity at a holding pressure when the mold cavity is about 90-99% filled by volume. In some embodiments, the holding pressure is 100±10 bar. In some embodiments, the holding pressure is 100±5 bar. In some embodiments, holding the mold cavity at a holding pressure occurs when the mold cavity is about 95-99% filled by volume. In some embodiments, holding the mold cavity at a holding pressure occurs when the mold cavity is about 99% filled by volume.

[0129] Enumerated Embodiments The specific enumerated embodiments 1-70 provided below are for illustrative purposes only and do not otherwise limit the scope of the disclosed subject matter, as defined by the claims. These enumerated embodiments include all combinations, subcombinations, and multiple-referenced (e.g., multiple-dependent) combinations described therein.

[0130] Enumerated Embodiments Relating to Helmet Covers Embodiment 1: A helmet cover, the helmet cover including a unitary shell assembly including a receiving cavity, an inner surface, and an outer surface, the receiving cavity configured such that the inner surface of the unitary shell assembly is configured to contact the outer surface of the helmet, and the unitary shell assembly conformably and removably covers the outer surface of the helmet.

[0131] Embodiment 2: A helmet cover as described in embodiment 1, wherein the one-piece shell assembly can fitably and removably cover the outer surface of the helmet without the use of adjustable fasteners.

[0132] Embodiment 3: The helmet cover of embodiment 1, wherein the helmet cover further comprises a finishing layer adhered to the outer surface of the unitary shell assembly.

[0133] Embodiment 4: A helmet according to any one of embodiments 1-3, wherein the unitary shell assembly further includes one or more openings therethrough corresponding to one or more openings in the helmet. Helmet cover.

[0134] Embodiment 5: A helmet cover described in any one of embodiments 1-4, wherein the unitary shell assembly further includes a gripping member.

[0135] Embodiment 6: A helmet cover as described in embodiment 5, wherein the gripping member is snap-fitably attached to the outer edge of the outer surface of the helmet.

[0136] Embodiment 7: A helmet cover according to any one of embodiments 1-5, wherein the one-piece shell assembly is made from a thermoplastic.

[0137] Embodiment 8: The helmet cover of embodiment 7, wherein the thermoplastic is polyurethane ("TPU"), polypropylene ("PP"), polyethylene ("PE"), polystyrene ("PS"), polyvinyl chloride ("PVC"), poly(methyl methacrylate) ("PMMA"), polycarbonate ("PC"), polyoxymethylene ("POM"), polyethylene vinyl acetate ("PEVA"), high density polyethylene ("HDPE"), acrylonitrile butadiene styrene ("ABS"), polyamide ("PA nylon"), or a mixture thereof.

[0138] Embodiment 9: A helmet cover according to embodiment 8, wherein the thermoplastic is TPU.

[0139] Embodiment 10: A helmet cover according to embodiment 9, wherein the TPU is TPU90, TPU95, or a blend.

[0140] Embodiment 11: A helmet cover according to any one of embodiments 7-10, wherein the unitary shell assembly is made from a thermoplastic, and the thermoplastic is present in at least 95% by weight.

[0141] Embodiment 12: A helmet cover according to any one of embodiments 7-11, wherein the unitary shell assembly is made from a thermoplastic, and the thermoplastic is present in at least 99% by weight.

[0142] Embodiment 13: A helmet cover described in any one of embodiments 7-12, wherein the one-piece shell assembly is made from thermoplastic, and the thermoplastic includes recycled thermoplastic from discarded and / or unused products.

[0143] Embodiment 14: A helmet cover according to any one of embodiments 1-13, wherein the unitary shell assembly is made from a thermoplastic and one or more additives.

[0144] Embodiment 15: The helmet cover of embodiment 14, wherein the one or more additives include color pigments, glitter, finishing surface chemicals, utility additives, and mixtures thereof.

[0145] Embodiment 16: The method of any one of embodiments 1-15, wherein the inner surface of the unitary shell assembly, the outer surface of the unitary shell assembly, or both, comprises a plurality of microperforations. Helmet cover.

[0146] Embodiment 17: A helmet cover as described in embodiment 16, wherein the plurality of microperforations is applied to less than the entire inner surface of the unitary shell assembly, less than the entire outer surface of the unitary shell assembly, or both.

[0147] Embodiment 18: A helmet cover described in any one of embodiments 16-17, wherein each of the plurality of microholes independently has a diameter of about 0.1 μm to 10 μm.

[0148] Embodiment 19: A helmet cover described in any one of embodiments 16-18, wherein each of the plurality of microperforations independently has a diameter of about 0.5 μm to 5 μm.

[0149] Embodiment 20: A helmet cover described in any one of embodiments 16-19, wherein each of the plurality of microperforations independently has a diameter of approximately 1 μm±0.5 μm.

[0150] Embodiment 21: A helmet cover described in any one of embodiments 16-20, wherein the plurality of micropores have an average diameter of 0.1 μm to 10 μm.

[0151] Embodiment 22: A helmet cover described in any one of embodiments 16-21, wherein the plurality of micropores have an average diameter of 0.5 μm to 5 μm.

[0152] Embodiment 23: A helmet cover described in any one of embodiments 16-22, wherein the plurality of microperforations have an average diameter of about 1 μm±0.5 μm.

[0153] Embodiment 24: The plurality of micropores is 3.2e9 to 3.2e5 micropores / cm 2 24. The helmet cover of any one of embodiments 16-23, having a distribution of:

[0154] Embodiment 25: The plurality of micropores is 1.3e8 to 1.3e6 micropores / cm 2 25. The helmet cover of any one of embodiments 16-24, having a distribution of:

[0155] Embodiment 26: The plurality of micropores is about 3.2e7 micropores / cm 2 26. The helmet cover of any one of embodiments 16-25, having a distribution of:

[0156] Embodiment 27: A helmet cover described in any one of embodiments 1-26, wherein the one-piece shell assembly has a thickness of 0.25 mm to 4 mm.

[0157] Embodiment 28: A helmet cover described in any one of embodiments 1-27, wherein the one-piece shell assembly has a thickness of approximately 1 mm ± 0.75 mm.

[0158] Embodiment 29: A helmet cover described in any one of embodiments 1-28, wherein the one-piece shell assembly has a thickness of approximately 1 mm ± 0.1 mm.

[0159] (Enumerated embodiments for methods of manufacturing a helmet cover) Embodiment 30: A method of manufacturing a helmet cover, the method comprising: A. Providing a polymer injection unit, the polymer injection unit comprising: (i) a barrel-mounted screw assembly, the barrel-mounted screw assembly including a screw mounted within a barrel; (ii) a processing space, the processing space including a distal end and a proximal end; (iii) one or more nozzles in fluid communication with the processing space, the one or more nozzles being disposed at a distal end of the processing space; With, B. Providing an injection mold tool, the injection mold tool including a mold cavity in fluid communication with a nozzle, the injection mold tool constructed to form a helmet cover in one piece; C. introducing a polymeric material into the processing space; D. melting the polymeric material in the processing space, wherein the melting is accomplished by using a screw mounted within the barrel to mix the polymeric material, applying a heat source to bring the polymeric material to a first predetermined temperature, and creating a predetermined back pressure; E. injecting a volume of polymeric material into the mold cavity through one or more nozzles, the volume of polymeric material being sufficient to fill the mold cavity; F. cooling the polymeric material in the mold cavity to a second predetermined temperature; G. Extracting the polymer material in the mold cavity from the injection mold tool and providing a helmet cover; A method comprising:

[0160] Embodiment 31: The method described in embodiment 30, wherein the helmet cover has the features described in any one of embodiments 1-29.

[0161] Embodiment 32: The method of any one of embodiments 30-31, wherein the method of manufacturing a helmet cover further comprises providing micro-perforations on the helmet cover.

[0162] Embodiment 33: The method of embodiment 32, wherein the microperforations are applied to less than the entire inner surface of the unitary shell assembly, less than the entire outer surface of the unitary shell assembly, or both.

[0163] Embodiment 34: The method of any one of embodiments 32-33, wherein each of the micropores independently has a diameter of 0.1 μm to 10 μm.

[0164] Embodiment 35: The method of any one of embodiments 32-34, wherein each of the micropores independently has a diameter of 0.5 μm to 5 μm.

[0165] Embodiment 36: The method of any one of embodiments 32-35, wherein each of the micropores independently has a diameter of about 1 μm±0.5 μm.

[0166] Embodiment 37: The method of any one of embodiments 32-36, wherein the micropores have an average diameter of 0.1 μm to 10 μm.

[0167] Embodiment 38: The method of any one of embodiments 32-37, wherein the micropores have an average diameter of 0.5 μm to 5 μm.

[0168] Embodiment 39: The method of any one of embodiments 32-38, wherein the micropores have an average diameter of about 1 μm±0.5 μm.

[0169] Embodiment 40: The micropores are 3.2e9 to 3.2e5 micropores / cm 2 40. The method of any one of embodiments 32-39, wherein the distribution is:

[0170] Embodiment 41: The micropores are 1.3e8 to 1.3e6 micropores / cm 2 The method of any one of embodiments 32-40, wherein the distribution is:

[0171] Embodiment 42: The micropores are about 3.2e7 micropores / cm 2 42. The method of any one of embodiments 32-41, wherein the distribution is:

[0172] Embodiment 43: A method according to any one of embodiments 30-42, wherein the method for manufacturing a helmet cover comprises melting a polymer material in a processing space by bringing the material to a first predetermined temperature.

[0173] Embodiment 44: The method of embodiment 43, wherein the first predetermined temperature is 230±30°C.

[0174] Embodiment 45: The method of any one of embodiments 43-44, wherein the first predetermined temperature is 230±20°C.

[0175] Embodiment 46: The method of any one of embodiments 43-45, wherein the first predetermined temperature is 230±15°C.

[0176] Embodiment 47: The method of any one of embodiments 43-46, wherein the first predetermined temperature is 230±5°C.

[0177] Embodiment 48: The method of any one of embodiments 30-47, wherein the method for manufacturing a helmet cover comprises generating a predetermined back pressure while melting the polymer material in the processing space.

[0178] Embodiment 49: The method of embodiment 48, wherein the predetermined backpressure is less than about 20 bar.

[0179] Embodiment 50: The method of any one of embodiments 48-49, wherein the predetermined backpressure is less than about 15 bar.

[0180] Embodiment 51: The method of any one of embodiments 48-50, wherein the predetermined backpressure is about 5±1 bar.

[0181] Embodiment 52: The method of any one of embodiments 30-51, wherein the method for producing a helmet cover includes cooling the polymeric material in the mold cavity to a second predetermined temperature.

[0182] Embodiment 53: The method described in embodiment 52, wherein the second predetermined temperature is 60±10°C.

[0183] Embodiment 54: The method described in any one of embodiments 52-53, wherein the second predetermined temperature is 60±8°C.

[0184] Embodiment 55: The method of any one of embodiments 52-54, wherein the second predetermined temperature is 60±6°C.

[0185] Embodiment 56: The method of any one of embodiments 52-55, wherein the second predetermined temperature is 60±4°C.

[0186] Embodiment 57: The method of any one of embodiments 52-56, wherein the second predetermined temperature is 60±2°C.

[0187] Embodiment 58: The method of any one of embodiments 30-57, wherein the method of manufacturing the helmet cover comprises injecting a volume of polymer material.

[0188] Embodiment 59: The method of embodiment 58, wherein injecting the volume of polymeric material is achieved by applying a first progressive pressure gradient.

[0189] Embodiment 60: The method of embodiment 59, wherein the progressive pressure gradient is from about 80 bar to about 10 bar.

[0190] Embodiment 61: The method of any one of embodiments 59-60, wherein the progressive pressure gradient is from about 70 bar to about 15 bar.

[0191] Embodiment 62: The method of any one of embodiments 58-61, wherein injecting the volume of polymeric material occurs within 20±20 seconds.

[0192] Embodiment 63: The method of any one of embodiments 52-62, wherein cooling the polymeric material in the mold cavity occurs within 60±20 seconds.

[0193] Embodiment 64: The method of any one of embodiments 58-63, wherein the steps of introducing a polymeric material into the processing space, melting the polymeric material in the processing space, injecting a volume of the polymeric material into the mold cavity through one or more nozzles, and cooling the polymeric material in the mold cavity occur within 130±40 seconds.

[0194] Embodiment 65: The method of any one of embodiments 58-64, wherein injecting a volume of polymeric material into the mold cavity through one or more nozzles further comprises holding the mold cavity at a holding pressure when the mold cavity is about 90-99% filled by volume.

[0195] Embodiment 66: The method of any one of embodiments 58-65, wherein injecting a volume of polymeric material into the mold cavity through one or more nozzles further comprises holding the mold cavity at a holding pressure when the mold cavity is about 95-99% filled by volume.

[0196] Embodiment 67: The method of any one of embodiments 58-66, wherein injecting a volume of polymer material into the mold cavity through one or more nozzles further comprises holding the mold cavity at a holding pressure when the mold cavity is about 99% filled by volume.

[0197] Embodiment 68: The method of any one of embodiments 65-67, wherein the holding pressure is 100±10 bar.

[0198] Embodiment 69: The method of any one of embodiments 30-68, wherein the polymeric material comprises a thermoplastic according to any one of embodiments 7-13.

[0199] Embodiment 70: The method of any one of embodiments 30-69, wherein the polymeric material comprises a thermoplastic of any one of embodiments 7-13 and one or more additives of any one of embodiments 14-15.

[0200] (Example) Example 1 The following table provides an exemplary commercially available helmet 102 over which a helmet cover 100 can be placed. [Table 1-1] [Table 1-2] [Table 1-3]

[0201] Example 2 The following description provides an example process specification for a method of manufacturing a helmet cover 100 via injection molding. The total cycle time for an injection molding method 600 using the example process specification is approximately 130 seconds. [Table 2]

[0202] Example 3 The following table provides exemplary specifications for a polymer material (TPU95) for use in a method of manufacturing a helmet cover 100 via injection molding. [Table 3]

Claims

[Claim 1] The invention described in this specification.

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