Oblique protrusion protection technology products, helmets including such technology products, sports supplies including such technology products, and processes therefor

Abstract

The oblique impact protection technology product component (20) includes a layer (50) of closed-cell foam including a first surface (52), a second surface (54), and a plurality of wells (56) on the first surface (52). The first surface (52) includes a plurality of first surface apertures (58), which are square. The second surface (54) faces the first surface (52) and optionally includes a plurality of second surface apertures (62). Each well (56) corresponds to a first surface aperture (58), and the second surface (54) is substantially parallel to or parallel to the first surface (52). A helmet (10) and / or sporting equipment (12) may include, and a process can manufacture, the technology product.

Description

Technical Field

[0001] The present invention relates to a technical product for protecting against oblique impacts, a helmet including such a technical product, and a method for manufacturing the same.

Background Art

[0002] Helmets are commonly used to protect a user's head from collisions and potential injuries caused by accidents and the like. Helmets may be suitable for specific situations such as sports helmets, for example, skiing, cycling, water sports, driving motorcycles and scooters, car racing, horseback riding, motocross / BMX, American football, snowboarding, boxing, skateboarding rugby, etc., and are well-known for use in maximizing head collision protection. Other helmets may be worn for protection in potentially dangerous situations, such as construction sites, accident and natural disaster sites, combat, firefighting, military policing activities, riots (riot helmets), etc. In other cases, helmets may be worn to assist in the proper shaping of an infant's head (skull orthosis) as it grows, for example, when a baby is born with a flat spot or other head deformity (i.e., positional plagiocephaly), and / or when the skull plates fuse improperly, causing craniosynostosis.

[0003] The process for making helmets is well-known and typically involves the use of blow molding, to which expandable materials such as foam and / or a foam precursor are added. The molding is typically heated before or during the process, and a vacuum is often applied to assist in the expansion of the foam and / or foam precursor. Various processes are also known for making foam articles, foam helmets, etc., such as injection molding (also known as in-moulding and co-injection moulding), steam chamber molding, steam pressure molding, etc. For example, injection molding is well-known in the art of helmets for combining a hard outer shell with an internal polystyrene shape. The process is well-known for adding an outer shell, or a painted outer shell, to expanded polystyrene, polystyrene foam, or other foam helmets. Some processes apply different materials to the molding simultaneously during the injection molding process (see, for example, US2015 / 01137709 A1 to Cheng, published April 30, 2015, which is incorporated herein by reference in its entirety), while other conventional processes form the parts separately first and then attach them together later.

[0004] Furthermore, there are various helmet standards for bicycle helmets, motorcycle helmets, etc. around the world. For example, the European Uniform Protective Helmet Standard ECE 22.05 (also known as "Regulation No. 22") can be found at: http: / / www.unece.org / trans / main / wp29 / wp29regs21-40.html, the European CSN Engineering Standard EN 1077 for Helmets for Alpine Skiers and Snowboarders (see https: / / www.en-standard.eu / csn-en-1077-helmets-for-alpine-skiers-and-snowboarders / ), the European CSN Engineering Standard EN 1078 for Helmets for Pedal Cyclists, Skateboarders, and Roller Skates (see https: / / www.en-standard.eu / csn-en-1078-a1-helmets-for-pedal-cyclists-and-for-users-of-skateboards-and-roller-skates / ), the European CNS European Engineering Standard EN 1384 for Helmets for Equestrian Activities (see https: / / www.en-standard.eu / csn-en-1384-helmets-for-equestrian-activities / ) and so on.

[0005] In addition, the United States Department of Transportation (DOT) has established other standards, such as Federal Motor Vehicle Safety Standard No. 218 regarding motorcycle helmets (also known as "49 CFR 571.218", "FMVSS 218", etc.) (see https: / / www.nhtsa.gov / document / tp-218-07pdf). Japanese standards include, for example, the riding helmet JSA JIS 8133-2007 (see http: / / www.freestd.us / soft / 136571.htm). In addition, additional national standards such as those of Australia and China for helmets are well-known in the art. Finally, the Snell Memorial Foundation further publishes its own standards, such as M2010 for motorcycle helmets.

[0006] In such tests, the helmets being tested are typically dropped at a given speed onto various anvils that are used to simulate the impact of the helmet on various surfaces. For example, a flat anvil mimics the helmet colliding with a flat pavement, while a hemispherical anvil or an inclined anvil mimics the helmet colliding with a curb at the edge of the road. All of those anvil types, impact speed / force, duration, etc. are described in the specific tests noted above.

[0007] Equipment suitable for testing helmets according to ECE, EN and / or JIS tests includes, for example, the 1002 MAU 1006 / CF / ALU - Monorail shock absorption test equipment available from AD Engineering s.r.l. of Bergamo, Italy. See, for example, http: / / www.adengin.it / en / products / 2_1002_MAU_1006_CF_ALU___Monorail_shock_ab.

[0008] However, it has gradually become clear that the types of collisions of the flat and hemispherical anvils described above are insufficient to accurately represent real-world conditions. Therefore, the amount of attention paid to protecting people from oblique impacts is increasing. The rationale is that the current test methods and requirements for flat and hemispherical anvils only represent the collisions that occur when the helmet hits the pavement at a 90° angle and when the helmet hits the curb. However, there is a growing recognition that most collisions occur when the helmet hits the pavement at an oblique angle. Furthermore, significant damage to soft tissues and the vertebrae of the spinal column can be caused by the torque transmitted in such oblique impacts, and thus there is a growing recognition that oblique impacts are a greater threat than previously recognized.

[0009] Therefore, various new helmet technology products are being developed to address the risk of oblique impacts (see, for example, https: / / www.singletracks.com / blog / mtb-gear / most-of-the-new-helmet-technologies-are-more-alike-than-different / ). Recent MIPS (Multi-Directional Impact Protection System, see https: / / mipsprotection.com) helmets include a low-friction, slightly movable frame / layer between the inner helmet surface and the user's (i.e., the wearer's) head.

[0010] By allowing a small amount of helmet slippage relative to the user's head at the moment of impact, the MIPS system is said to provide improved protection against oblique impacts because reduced forces are transmitted to the user.

[0011] While MIPS is currently the gold standard for oblique impact protection, it is designed only for oblique impact protection and by itself does not provide significant protection against direct vertical impacts.

[0012] Bontrager's WaveCel (https: / / wavecel.trekbikes.com / us / en_US / ) is a technical product formed from a foldable open cell structure, and this technical product is arguably more functional than MIPS because of its foldability. However, this discussion is currently being debated by MIPS and other industry players.

[0013] Koroyd uses a dual-core straw-like material to form an impact-absorbing zone in helmets that protect against various collisions. For example, this technical product may be used in combination with MIPS.

[0014] Another technical product for achieving a similar effect is the SPIN (Shearing Pad INside) rotational protection system, which attaches a silicone gel pad between the inner helmet surface and the user's head.

[0015] These gel pads allow the helmet to shear in any direction during an angled impact and further reduce the impact force transmitted to the user's head. In contrast, Fox's Fluid system attempts to mimic the properties of cerebrospinal fluid with fluid pods in the helmet to reduce damage from angled impacts.

[0016] Kali and Leatt use Armourgel material, a cushioning smart material that contracts to absorb impact force and allow for lower transmission of angled impact forces. Kali uses Amourgel to form their LDL (low density layer), which is shaped as strips containing small cups that harden during a collision. Leatt's 360° Turbine technology uses small blue Amourgel foam discs located at key head sites, which is said to allow both cushioning for direct impacts and slipperiness to reduce the force transmitted to the user during an angled impact.

[0017] The 6D Helmet's ODS (Omni-Directional Suspension, see, for example, https: / / www.6dhelmets.com / innovation / ) essentially forms two concentric helmets having a suspension layer therebetween. The ODS system is said to provide the user with both linear and angled impact protection. However, such a system involves substantial manufacturing complexity in essentially creating two separate helmets with tight tolerances. Thus, such helmets can be expensive, difficult to manufacture, thicker, and bulkier.

[0018] Shred uses strategically placed discs that are said to reduce the rotational impact forces transmitted to the user during angled impacts.

[0019] However, current systems suffer from various demerits such as increased cost, increased materials, increased manufacturing complexity, increased weight, complexity, reduced ventilation, reduced flexibility, and / or discomfort. Thus, there continues to be a need for improved helmets and improved helmet molding processes that address the problems associated with angled impacts. SUMMARY OF THE INVENTION

[0020] Embodiments of the present invention relate to angled impact protection technology products including a closed cell self-form layer including a first surface, a second surface, and a plurality of wells on the first surface. The first surface includes a plurality of first surface apertures, and the first surface apertures are square. The second surface faces the first surface and optionally includes a plurality of second surface apertures. Each well corresponds to a first surface aperture, and the second surface is substantially parallel or parallel to the first surface.

[0021] Embodiments of the present invention relate to helmets including angled impact protection technology products. Embodiments of the present invention relate to sports equipment including angled impact protection technology products.

[0022] Embodiments of the present invention relate to a process for manufacturing a helmet by providing a molded portion of the female part, a molded portion of the male part, a member of a vehicle collision protection technology product including the vehicle collision protection technology product of the present specification, and a collision dissipation material. The molded portion of the male part is complementary to the molded portion of the female part, and thus the molded portion of the female part and the molded portion of the male part are integrally adaptable so that they form a hollow molding therebetween. Before the molded portion of the male part and the molded portion of the female part are integrally adapted, or after the molded portion of the male part and the molded portion of the female part are integrally adapted, the member of the vehicle collision protection technology product is applied to the male part portion.

[0023] In the manufacturing process, the collision dissipation material is applied to the hollow molding in the form of a liquid or a plurality of beads, or as a plurality of beads. The member of the vehicle collision protection technology product and the collision dissipation material are subjected to an injection molding process within the hollow molding. In the process of the present specification, the collision dissipation material forms a collision dissipation member having an inner surface of the collision dissipation member and an outer surface of the collision dissipation member facing the inner surface of the collision dissipation member. The injection molding process permanently bonds the member of the vehicle collision protection technology product, typically the outer surface of the member of the vehicle collision protection technology product, to the inner surface of the collision dissipation member.

[0024] Without being limited by theory, the invention herein is believed to reduce potential trauma to the head, spine, skeleton, and / or soft tissue by reducing the amount of force and / or torque transmitted to the user's body or head during an angled impact event. Specifically, the configuration of the first surface including a plurality of wells is believed to allow both a layer of closed cells to provide a comfortable fit and allow for lateral and transverse flexion of the layer. This allows the layer to reduce rotation and / or torque of the helmet before the helmet transmits the resulting force and / or torque to the user's head. Additionally, the present invention is believed to provide significant protection from both conventional (i.e., 90°) impacts and angled impacts. In addition thereto, the present invention is believed to provide significant or improved protection while simultaneously reducing raw materials, reducing manufacturing complexity, reducing cost, reducing waste, reducing manufacturing time per helmet, and improving breathability and / or ventilation for the user. In addition thereto, the angled impact protection technology product is believed to be highly adaptable in that it can be widely applied by those skilled in the art to a variety of helmets, numerous sports equipment, etc. with little or no additional modification required thereto. BRIEF DESCRIPTION OF THE DRAWINGS

[0025]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

[0026] The drawings in this specification are for illustrative purposes only and are not necessarily drawn to an exact scale.

DETAILED DESCRIPTION OF THE INVENTION

[0027] Unless otherwise specified, all tests in this specification are conducted under standard conditions including an indoor temperature and test temperature of 25°C, a pressure at sea level (1 atm.), and, where relevant, a pH of 7, and all measurements are made in metric units. Further, unless otherwise indicated, all percentages, ratios, etc. in this specification are by weight. Unless otherwise noted, the materials, components, compounds, chemicals, etc. described in this specification are understood to be typical items and / or industry standard items available from various sources around the world.

[0028] Unless otherwise explicitly indicated, as used in this specification with respect to a helmet, the terms “inner surface” and “inside” indicate the relative position with respect to the helmet portion that is close to or near the wearer's head. Unless otherwise explicitly indicated, as used in this specification with respect to a helmet, the terms “outer surface” and “outside” indicate the relative position with respect to the helmet portion that is far from or away from the wearer's head and close to the outside of the helmet.

[0029] Embodiments of the present invention relate to an oblique impact protection technology product including a closed self - forming layer including a first surface, a second surface, and a plurality of wells on the first surface. The first surface includes a plurality of first surface apertures, and the first surface apertures are square. The second surface faces the first surface and optionally includes a plurality of second surface apertures. Each well corresponds to a first surface aperture, and the second surface is substantially parallel or parallel to the first surface.

[0030] Without being bound by theory, it is believed that the invention herein can reduce potential trauma to the head, spine, skeleton and / or soft tissue by reducing the amount of force and / or torque transmitted to the user's body or head during an oblique impact event, as well as during a conventional (i.e., 90°) impact. Specifically, the configuration of the first surface including a plurality of wells is believed to enable both a closed cell layer to provide a comfortable fit and to allow lateral and transverse flexion of the layer. This enables the layer to reduce the rotation and / or torque of the helmet before the helmet transmits the resulting force and / or torque to the user's head.

[0031] Furthermore, it will be appreciated that the first surface is in frequent contact with the user's body or head during use. It has been found that if the first surface has a large surface area, the layer may not significantly reduce the force and / or torque transmitted to the user's body or head. Thus, the design of the present invention is considered optimized such that the first surface gently but firmly grips the user's head while the walls of the wells can compress and / or flex to absorb a portion of the overall force from an oblique impact. This is thought to reduce the total amount of force and / or torque transmitted to the user's body or head during an accident.

[0032] Closed cell foams useful herein are typically foams containing a plurality of independent air bubbles. Closed cell foams typically include closed cell foam materials selected from the group consisting of styrene-butadiene rubber, polyurethane foam, polyethylene foam, ethylene vinyl acetate foam, latex foam, polyvinyl chloride foam, vinyl nitrile foam and combinations thereof, or acrylic polyethylene foam, polyurethane foam, ethylene vinyl acetate foam, polyvinyl chloride foam, vinyl nitrile foam and combinations thereof, or polyurethane foam, latex foam, rubber foam, polyvinyl chloride foam, vinyl nitrile foam and combinations thereof, or vinyl nitrile foam.

[0033] Closed cell foam materials typically have a melting point of about 60 °C to about 250 °C, or about 80 °C to about 180 °C, or about 90 °C to about 160 °C. In one embodiment of the present specification, the density of the closed cell foam material is about 0.1 g / cm3 to about 0.5 g / cm3, or about 0.15 g / cm3 to about 0.4 g / cm3, or about 0.175 g / cm3 to about 0.35 g / cm3. In one embodiment of the present specification, the hardness of the layer is about 20 to about 85, or about 25 to about 75, or about 30 to about 70.

[0034] Without intending to be limited by theory, the temperature range of such closed cell foam materials is thought to maintain a balance of desired properties such as toughness, the ability to permanently bond to other helmet components, and comfort. Such materials are well known in technical fields such as helmet manufacturing and insulation, and various quality grades and characteristics are available from multiple suppliers worldwide.

[0035] In one embodiment of the present specification, the surface area of the first surface aperture is 25% or more of the surface area of the corresponding first surface, or about 25% to about 95% of the surface area of the corresponding first surface, or about 35% to about 90% of the surface area of the corresponding first surface, or about 45% to about 85% of the surface area of the corresponding first surface, or about 50% to about 80% of the surface area of the corresponding first surface. As used herein, the surface area of the corresponding first surface and / or the corresponding second surface is calculated as the total surface area including the surface area of the aperture.

[0036] In one embodiment of the present specification, the first surface is substantially parallel or parallel to the second surface. Typically, the thickness of the layer is about 0.5 mm to about 2 cm, or about 1 mm to about 1.5 cm, or about 2 mm to about 1.2 cm, or about 0.3 to about 1 cm, as measured from the first surface to the second surface.

[0037] The first surface of this specification refers to the surface of the layer or the surface formed by the uppermost surface of the layer. In one embodiment of this specification, the first layer is intended to touch the user's body or head and / or be the surface of the oblique impact protection technology product closest to the user's body or head.

[0038] The first surface aperture of this specification is square because such a shape is considered to provide improved advantages compared to other shapes. Various shapes such as hexagonal, circular, etc. have been tested, and overall, considering various factors such as functionality, force / torque absorption, comfort, etc., the square has been confirmed to be the most preferred. Without intending to be limited by theory, during an oblique impact, it is considered that the layer bends and rotates around the user's body or head to reduce the force / torque transmitted to them. Generally, angular shapes are considered to be able to accumulate / concentrate forces at these positions during an oblique impact. In contrast, the circular shape of the first surface aperture theoretically avoids the concentration of impact forces, but it has been found that using a circle forms too large a surface area between the first surface apertures, which makes the layer uncomfortable and reduces its effect. Furthermore, polygonal shapes such as hexagonal apertures are considered to contain too many corners (where forces / torques will concentrate). Therefore, when the first aperture includes a square, this is considered to provide an optimal balance of, for example, force / torque reduction, comfort, and breathability. Additionally, sharp angles are considered to be able to concentrate forces unnecessarily. Therefore, in the embodiments of this specification, the square includes rounded corners or four rounded corners.

[0039] The second surface is typically parallel to the first surface and may include a second surface aperture or a plurality of second surface apertures. In one embodiment of this specification, the second surface aperture has a shape, or a shape selected from the group of square, circular, oval, and combinations thereof, or is circular or oval, or has a circle.

[0040] The layer further includes a plurality of wells on the first surface, and each well corresponds to a first surface aperture. Essentially, each first surface aperture forms an opening of the well. The wells are considered to be very important. This is because a larger proportion of the capacity of the wells in the layer results in thinner walls, and thus the walls can bend and deform more, reducing the force / torque transmitted to the user's body or head. Therefore, one skilled in the art must balance a larger well capacity that results in reduced force / torque transmission with factors such as comfort, the sense that the helmet (or other article) is safe, and not slipping significantly during normal use.

[0041] In one embodiment of the present specification, as measured by the test of modified Regulation No. 22 using a 45° anvil instead of a normal flat and hemispherical anvil, compared to a similar helmet without a glancing impact protection technology product, the glancing impact protection technology product reduces the glancing impact force / torque transmission by at least 10%, or about 10% to about 50%, or about 12% to about 45%, or about 13% to about 40%.

[0042] In one embodiment of the present specification, in addition to the reduction in glancing impact force / torque transmission, as measured by the test of Regulation No. 22 using a flat anvil (i.e., a conventional 90° collision) and / or a hemispherical anvil, compared to a similar helmet without a glancing impact protection technology product, the glancing impact protection technology product further reduces the transmission of impact force by at least 2%, or about 2% to about 50%, or about 3% to about 45%, or about 4% to about 40%.

[0043] The wells in this specification may pass partially through the layer, in which case it is characterized as a closed well, or may pass through the entire layer, in which case it is characterized as an open well. The depth of the well of the closed well is typically 25% or more of the thickness of the layer, or about 25% to about 99% of the thickness of the layer, or about 35% to about 95% of the thickness of the layer, or about 45% to about 90% of the thickness of the layer. The well depth is measured from the first surface, or the plane of the first surface, to the well bottom if the well bottom exists (i.e., for a closed well). Typically, the well bottom is the point in the well that is farthest from the first surface, or the plane of the first surface, as measured perpendicularly from the first surface, or the plane of the first surface. If the well passes completely through the layer (e.g., the well is an open well) and there is no well bottom, the well depth is defined as 100% and is equal to the thickness of the layer.

[0044] Thus, in embodiments of this specification, one well of a plurality of wells is a closed well, or at least 25% of the plurality of wells are closed wells, or at least 50% of the plurality of wells are closed wells, or here, substantially all of the plurality of wells are closed wells, or all of the plurality of wells are closed wells.

[0045] In the case of an open well, one of ordinary skill in the art would understand that the depth of the well is 100% of the thickness of the layer in order for the well to form a path completely through the layer. Thus, in embodiments including an open well, the first surface aperture corresponds to the well, and the first surface aperture and / or the well further corresponds to the second surface aperture. In other words, the open well forms a path connecting the first surface aperture to the corresponding second surface aperture. In one embodiment herein, one of a plurality of wells is an open well, and the well corresponds to the second surface aperture, or at least 25% of the plurality of wells corresponds to the second surface aperture, or at least 50% of the plurality of wells corresponds to the second surface aperture, or substantially all of the plurality of wells corresponds to the second surface aperture, or all of the plurality of wells corresponds to the second surface aperture.

[0046] In one embodiment herein, one of a plurality of wells is an open well, and the well corresponds to the second surface aperture, thereby forming a path from the first surface to the second surface, or at least 25% of the plurality of wells corresponds to the second surface aperture, thereby forming a plurality of paths from the first surface to the second surface, or here, at least 50% of the plurality of wells corresponds to the second surface aperture, thereby forming a plurality of paths from the first surface to the second surface, or substantially all of the plurality of wells corresponds to the second surface aperture, thereby forming a plurality of paths from the first surface to the second surface, or all of the plurality of wells corresponds to the second surface aperture, thereby forming a plurality of paths from the first surface to the second surface. In one embodiment herein, substantially all of the wells are open wells.

[0047] In one embodiment of the present specification, the oblique impact protection technology products of the present specification are included in sports supplies selected from the group consisting of footwear, bodywear, face masks, helmets, rackets, clubs, and combinations thereof, or footwear, bodywear, helmets, and combinations thereof. In one embodiment of the present specification, the footwear useful in the present specification may include, for example, shoes, sandals, etc., or basketball shoes, running shoes, ski boots, etc. In one embodiment of the present specification, the bodywear useful in the present specification may include, for example, protective pads, clothing, wet suits, etc., or shoulder pads, knee pads, shin pads, protective exteriors, etc. In one embodiment of the present specification, the oblique impact protection technology products of the present specification are included in helmets such as sports helmets.

[0048] The helmets useful in the present specification typically include a collision dissipation member and an oblique impact protection technology product directly or indirectly attached to the inner surface of the collision dissipation member. The collision dissipation member has an inner surface of the collision dissipation member and an outer surface of the collision dissipation member facing the inner surface of the collision dissipation member. The collision dissipation materials useful in the present specification are typically selected from polystyrene, polypropylene, and mixtures thereof, or extruded polystyrene, expanded polystyrene, expanded polypropylene, and mixtures thereof, or expanded polystyrene, and mixtures thereof.

[0049] Embodiments of the present specification include a shell that is external to and typically permanently joined to the outer surface of the impact dissipation member. The shell typically covers most, if not all, of the outer surface of the impact dissipation member and serves multiple purposes such as aesthetics, additional impact dissipation, and friction reduction. In one embodiment of the present specification, the shell comprises a shell material selected from polycarbonate, polystyrene, polyacrylate, and mixtures thereof, or from extruded polystyrene, expanded polystyrene, and mixtures thereof, or from expanded polystyrene and mixtures thereof. Typically very thin, the shell includes an inner surface of the shell and an outer surface of the shell that faces the inner surface of the shell. The inner surface of the shell is typically further permanently bonded to the outer surface of the impact dissipation member, for example, during an injection molding process. Alternatively, the shell may be bonded to the outer surface of the impact dissipation member via an adhesive or other methods well known in the art after its formation.

[0050] The oblique impact protection technology product may be attached to the impact dissipation member and / or another helmet part via a technique selected from the group consisting of, for example, adhesion, injection molding, heat fusion, ultrasonic fusion, and combinations thereof, or injection molding. For example, reference is made to the description of a general helmet together with process-related information as seen in US2015 / 01137709 A1 to Cheng, published on April 30, 2015.

[0051] Manufacturing process: The process of manufacturing the helmet of the present specification typically includes providing a molded portion of the female part, providing a molded portion of the male part, providing an oblique impact protection technology product member including the oblique impact protection technology product of the present specification, and providing an impact dissipation material. The molded portion of the male part is complementary to the molded portion of the female part, and thus the molded portion of the female part and the molded portion of the male part can be combined such that they form a hollow molding therebetween. The oblique impact protection technology product member is applied to the male part portion before the molded portion of the male part and the molded portion of the female part are combined, or after the molded portion of the male part and the molded portion of the female part are combined.

[0052] The impact dissipation material can be applied to blow molding in the form of a liquid or a plurality of beads, or as a plurality of beads. The oblique impact protection technology product member and the impact dissipation material are exposed to an injection molding process in blow molding. In the process of this specification, the impact dissipation material forms an impact dissipation member having an inner surface of the impact dissipation member and an outer surface of the impact dissipation member facing the inner surface of the impact dissipation member. The injection molding process permanently bonds the oblique impact protection technology product member, typically the outer surface of the oblique impact protection technology product member, to the inner surface of the impact dissipation member. Additional other parts may also be formed therein, thereon, or on the side of various helmet components such as a shell, a mounting area, a frame, a reflector, etc. at this time. In one embodiment of this specification, the shell material is typically provided and applied to the female part before or during the injection molding process. In this embodiment, the shell material forms a shell, and the injection molding process permanently bonds the shell or the inner surface of the shell to the outer surface of the impact dissipation member.

[0053] The injection molding process and machine typically perform the injection molding process at a temperature of about 65°C to about 250°C, or about 80°C to about 180°C, or about 90°C to about 160°C. Such processes and related machines are well-known in the art and are available from various manufacturers around the world.

[0054] The oblique impact protection technology product member may be formed from a closed cell foam, from a closed cell foam material, and / or from one or more closed cell foam precursors by methods known in the art such as vacuum molding, foaming, etc.

[0055] Drawings: Next, looking at the drawings, FIG. 1 is a side view of a portion of an embodiment of a helmet (10) according to the present invention. The helmet (10) typically also includes a complementary or mirror-image left side view, which is not shown here for the sake of brevity. The helmet (10) is an example of a type of sports equipment (12) and has an anti-ramming protection technology product member (20) with an inner surface (22) of the anti-ramming protection technology product member and an outer surface (24) of the anti-ramming protection technology product member. The outer surface (24) of the anti-ramming protection technology product member faces the inner surface (22) of the anti-ramming protection technology product member (i.e., is on the opposite side).

[0056] The helmet (10) further includes a collision dissipation member (26) formed from a collision dissipation material. The helmet (10) includes holes (28) that allow air to flow through the helmet (10) when worn, thereby increasing user comfort and breathability. The helmet (10) often includes a plurality of holes (28), which further reduces the weight of the helmet and cuts down on the amount of material and manufacturing costs. A plurality of ribs (30) are connected through between the holes (28), and these are made from the collision dissipation material. Thus, the ribs (30) form the structural basis of the collision dissipation member (26) of the helmet (10). A plurality of anti-ramming protection technology product members (20) are found inside the helmet (10), and each of them is permanently attached, or permanently joined, or injection molded with the collision dissipation member (26), often with ribs (30), between the holes (28). Specifically, the outer surface (24) of the anti-ramming protection technology product member is typically injection molded with ribs (30) onto the collision dissipation member (26). The collision dissipation member (26) includes an outer surface (34) of the collision dissipation member.

[0057] The helmet (30) further includes a shell (32) outside the collision dissipation member (26) and covering most of the collision dissipation member (26). The shell (32) has an inner surface (36) of the shell and is permanently joined to the outer surface (34) of the collision dissipation member. The outer surface (38) of the shell is open to the air and is the part of the helmet farthest from the user's head (not shown).

[0058] The helmet (10) has additional features (40) that are further injection molded onto the impact dissipation member (26). In this case, the additional features are, for example, buckles for attaching a chin strap (not shown). The helmet (10) further includes another additional feature (40’), which in this case is, for example, a screw hole for a screw that can be used to attach an insert for a small-headed wearer.

[0059] Figure 2 shows a partial, top surface perspective enlarged view of an embodiment of a side impact protection technology product member (20) useful in this specification. The side impact protection technology product member (20) is formed from a closed cell foam layer (50) and includes a first surface (52) and a second surface (54). Those skilled in the art will understand that only a small portion of the layer (50) is shown in Figure 2. The first surface (52) includes a plurality of wells (56). In Figure 1, each well (56) corresponds to a first surface aperture (58), and each of them is a square having four rounded corners (60). The layer (50) is, for example, when attached to one sports equipment (see (12) in Figure 1) or a helmet (see (10) in Figure 1), it will typically be the second surface (54) that is attached to one sports equipment (see (12) in Figure 1) or a helmet (see (10) in Figure 1). In this embodiment, all of the wells (56) are seen to be the same in shape and size, all of the first surface apertures (58) are the same in shape and size, and all of the second surface apertures (62) are the same in shape and size.

[0060] In Figure 2, each second surface aperture (62) corresponds to the first surface aperture (58), and each corresponding well (56), in this case the open well (64), forms a path (66) between the first surface (52) and the second surface (54). There is a well wall (68) between well (56’) and well (56”), which provides structural integrity to the layer (50) and is seen to further bend and / or deform upon impact so as to reduce the force / torque transmitted to the user. In this embodiment, the transition between the first surface aperture (58) and the well (56) is further seen to include a rounded end (70), which may make the manufacture of the layer (50) easier and further provide greater comfort to the user.

[0061] Figure 3 shows a partial, bottom perspective enlarged view of an embodiment of an impact protection technology product member (20) useful herein. This drawing clearly shows the second surface (54) including a plurality of second surface apertures (62) and a plurality of wells (56), (56’), (56”). The first surface (52) faces the second surface (54). Figure 3 further clearly shows that a well wall (68) is formed between well (56’) and well (56”).

[0062] Figure 4 shows a partial plan view of an embodiment of the oblique impact protection technology product member (20) of FIG. 1. This drawing is taken from above the first surface (52) and clearly shows the first surface aperture (58). The surface area of the square first surface aperture (58) may be calculated by measuring the width (AW) of the first surface aperture and the length (AL) of the first surface aperture, multiplying them, and subtracting the surface area between the corresponding rounded corners (60). The surface areas of other non-square surface apertures may be calculated similarly by geometric principles and / or formulas well-known in the art or by computer-aided design (CAD) programs. In FIG. 4, the width (AW) of the first surface aperture is the farthest distance between any opposing ends, while the length of the first surface aperture is measured as the farthest distance between any opposing ends perpendicular to the direction of the width of the first surface aperture. Similarly, the surface area of the corresponding first surface may be calculated by measuring the distances from the midpoints between each first surface aperture (58) to calculate the width (SA) and length (SL) of the first surface, and then multiplying the width (SA) and length (SL) of the first surface.

[0063] Figure 5 shows a partial side view of an embodiment of the oblique impact protection technology product member (20) of FIGS. 1 and 4. This drawing shows that the first surface (52) forms the first surface plane (FSP), while the second surface (54) forms the second surface plane (SSP) parallel to the first surface plane (FSP). Further, it will be apparent that the width (AW) of the first surface aperture of the first surface aperture (58) is measured from a point with the well wall (68) to the point where the first surface aperture (58) breaks (opposite) the first surface plane (FSP). Further, for clarity, it is shown that the width (AW) of the first surface aperture is measured at an angle perpendicular to the first surface plane (FSP).

[0064] The thickness (LT) of the layer is the distance between the first surface plane (FSP) and the second surface plane (SSP) as measured perpendicular to the first surface plane (FSP), and in FIG. 5, this is shown to be substantially the same throughout the layer (50). In this drawing, it will be further understood that the depth (WD) of the well is equal to 100% of the thickness of the layer (LT). This is because the well (56) is an open well (64) which forms a path (66) from the first surface (and the first surface plane (FSP)) to the second surface (and the second surface plane (SSP)). In this drawing, a plurality of second surface apertures (62) may also be seen.

[0065] FIG. 6 shows a partial side view of an embodiment of an anti - penetration technology product member (20). This drawing shows a layer (50) having a first surface (52) and a second surface (54) opposite the first surface (52). The first surface aperture (58) corresponds, at the first surface (52), to a well (56) having a well wall (68). The first surface (52) forms the first surface plane (FSP), and the second surface (54) forms the second surface plane (SSP).

[0066] However, in this embodiment, each of the wells (56) is a closed well (72) having a rounded end (70) and a well floor (74). Shallow second surface apertures (62) are shown in this embodiment, and the second surface apertures (62) neither connect to the first surface aperture (52) nor form a path (see (66) in FIG. 4), but there is a (74’) serving as a well floor.

[0067] FIG. 7 is a schematic view of a 45° anvil (76) and an associated helmet test. The helmet (20) is securely attached to the head shape (78) and accelerated in a controlled manner in the direction indicated by arrow A towards the 45° anvil (76). The 45° anvil (76) has a collision surface (80) at an angle (α) which is 45° with respect to the direction of fall of arrow A and also 45° with respect to a normal flat anvil surface (FA).

[0068] When impacted, the helmet (20) rebounds in a direction generally indicated by arrow B from the impact surface (80).

[0069] Test process: The test of the helmet for the oblique impact performance in this specification is performed using an industry standard organization such as that described in Regulation No. 22, except that the anvil is a 45° anvil, which has an impact surface at an angle of 45° from the normal and flat anvil used in the normal test of Regulation No. 22 (i.e., "Modified Regulation No. 22 test with 45° anvil"). For example, see Figure 7. The head shape includes sensors (e.g., accelerometers), or a plurality of sensors, to measure the velocity, acceleration, etc. of the head shape in three dimensions. In addition, a high-speed camera may also be present to record the test.

[0070] <Example> <Example 1> The oblique impact protection material is manufactured from a closed cell foam material, attached to a pre-formed helmet with an industry standard contact adhesive, and labeled as Helmet A. Manufacture the same helmet except without the oblique impact protection material and label it as Comparative Helmet A1. Manufacture a comparable helmet including the MIPS system and label it as Comparative Helmet A2.

[0071] Using flat and hemispherical anvils in the regular test of Regulation No. 22 and dropped from a height of 205 cm, the average peak G value of Helmet A is 4.7% less than that of Comparative Helmet A1 and 2.4% less than that of Comparative Helmet A2. Therefore, this data indicates that the present invention provides improved linear impact protection (i.e., less force transmission) compared to the comparative helmets.

[0072] <Example 2> The oblique impact protection material is manufactured from a closed cell foam material, attached to a pre-formed helmet with an industry standard contact adhesive, and labeled as helmet B. Manufacture the same helmet except without the oblique impact protection material and label it as comparative helmet B1. Manufacture a comparable helmet including the MIPS system and label it as comparative helmet B2. Manufacture a comparable helmet including the KALI's LDL system and label it as comparative helmet B3.

[0073] These helmets were tested using the Modified Regulation No. 22 test with 45° anvil as described herein and dropped from a height of 210 cm. The data collected included measurements of the front, X-axis rotation, Y-axis rotation, Z-axis rotation, occipital and side-R from the head shape (measured in radians / second²). The average rotation of helmet B was 14.1% less than that of comparative helmet B1, 3.3% less than that of comparative helmet B2, and 7.5% less than that of helmet B3. Thus, this data shows that the present invention provides improved rotational impact protection (i.e., less force / torque transmission) compared to the comparative helmets.

[0074] <Example 3> The oblique impact protection material is manufactured from a closed cell foam material, attached to a pre-formed helmet with an industry standard contact adhesive, and labeled as helmet C. Manufacture the same helmet except without the oblique impact protection material and label it as comparative helmet C1. Manufacture a comparable helmet including the MIPS system and label it as comparative helmet C2.

[0075] These helmets were tested using the Modified Regulation No. 22 test with 45° anvil as described herein and dropped from a height of 210 cm. The data collected included measurements of the front, rear, left, right, and top from the head shape (measured in radians / second²). The average rotation of Helmet B was 15.5% less than that of Comparative Helmet C1 and 15.7% less than that of Comparative Helmet C2. Thus, this data shows that the present invention provides improved rotational impact protection (i.e., less force / torque transmission) compared to the comparative helmets.

[0076] It should be understood that the above merely illustrates and describes examples in which the present invention may be practiced and that modifications and / or changes thereto may be made without departing from the spirit of the present invention.

[0077] It should also be understood that the specific features of the present invention described in the context of separate embodiments may be provided in combination in a single embodiment. Conversely, for the sake of brevity, the various features of the present invention described in the context of a single embodiment may also be provided separately or in any suitable sub - combination.

[0078] All references specifically cited herein are hereby incorporated by reference in their entirety. However, the citation or incorporation of such references is not an admission as to their propriety, citable - ness, and / or availability as prior art with respect to or against the present invention.

Claims

1. An oblique impact protection technology product, wherein the oblique impact protection technology product comprises A) a closed cell self-form layer, and the closed cell self-form layer comprises i) a first surface including a plurality of first surface apertures, wherein the first surface apertures include squares, and the surface area of the first surface apertures is 25% or more of the surface area of the first surface, the first surface, ii) a second surface facing the first surface, and iii) a plurality of wells within the first surface, wherein each well corresponds to the first surface aperture, a plurality of wells, and wherein the second surface is parallel to the first surface, an oblique impact protection technology product.

2. The oblique impact protection technology product according to claim 1, wherein the second surface includes a plurality of second surface apertures.

3. The oblique impact protection technology product according to any one of claims 1 or 2, wherein each second surface aperture corresponds to a first surface aperture.

4. The oblique impact protection technology product according to any one of claims 1 to 3, wherein one of the plurality of wells is a closed well.

5. The oblique impact protection technology product according to any one of claims 1 to 4, wherein one of the plurality of wells corresponds to a second surface aperture.

6. The oblique impact protection technology product according to any one of claims 1 to 5, wherein one of the plurality of wells is an open well, and the open well corresponds to a second surface aperture, thereby forming a path from the first surface to the second surface.

7. The oblique impact protection technology product according to any one of claims 1 or 6, wherein the thickness of the layer is about 0.5 mm to about 2 cm as measured from the first surface to the second surface.

8. The oblique impact protection technology product according to any one of claims 1 to 7, wherein the square includes rounded corners or four rounded corners.

9. The closed cell self-form includes a closed cell self-form material selected from the group consisting of foam rubber, polyurethane foam, polyethylene foam, ethylene vinyl acetate foam, latex foam, polyvinyl chloride foam, vinyl nitrile foam, and combinations thereof. The oblique impact protection technology product according to any one of claims 1 to 8.

10. A helmet comprising the anti-angled-impact protection technology product according to any one of claims 1 to 9.

11. The helmet according to claim 10, wherein the anti-angled-impact protection technology product is attached to the helmet by a technique selected from the group consisting of adhesion, injection molding, heat fusion, ultrasonic fusion, and combinations thereof, or by injection molding.

12. The helmet according to any one of claims 10 to 11, wherein the anti-angled-impact protection technology product reduces the transmission of the force / torque of the angled impact on the helmet by at least 10% in a collision test (modified Regulation No. 22 test with 45° anvil) against an anvil having a collision surface at an angle of 45° to the horizontal, based on UN Regulation No. 22 adopted by the mutual recognition agreement of type approvals of vehicles, devices, etc. of the United Nations.

13. A process for manufacturing a helmet, the process comprising: A. providing a molding portion of the female part; B. providing a molding portion of the male part complementary to the molding portion of the female part, wherein the molding portion of the female part and the molding portion of the male part are integrally adaptable to form a hollow molding therebetween; C. providing an anti-angled-impact protection technology product member including the anti-angled-impact protection technology product according to any one of claims 1 to 9; D. applying the anti-angled-impact protection technology product member to the molding portion of the male part; E. providing a collision dissipation material and applying the collision dissipation material into the hollow molding, wherein the anti-angled-impact protection technology product member and the collision dissipation material are subjected to an injection molding process within the hollow molding, wherein the anti-angled-impact protection technology product member includes an inner surface of the anti-angled-impact protection technology product member, wherein the anti-angled-impact protection technology product member includes an outer surface of the anti-angled-impact protection technology product member facing the inner surface of the anti-angled-impact protection technology product member, wherein the collision dissipation material forms a collision dissipation member including an inner surface of the collision dissipation member, wherein the collision dissipation member includes an outer surface of the collision dissipation member facing the inner surface of the collision dissipation member, wherein the injection molding process permanently bonds the outer surface of the anti-angled-impact protection technology product member to the inner surface of the collision dissipation member.

14. The process according to claim 13, wherein the injection molding process is performed at a temperature of 65°C to 250°C.

15. A sports product comprising the oblique impact protection technology product according to any one of claims 1 to 9.

16. The sports product according to claim 15, wherein the sports product is selected from the group consisting of footwear, bodywear, face masks, helmets, rackets, clubs, and combinations thereof.

17. The sports product according to any one of claims 15 to 16, wherein the oblique impact protection technology product is attached to the sports product by a process selected from the group consisting of adhesion, injection molding, heat fusion, ultrasonic fusion, and combinations thereof.

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