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 of related applications) This application claims priority to U.S. Patent Application No. 17 / 664,892, filed on 25 May 2022, which in turn claims priority to U.S. Provisional Patent Application No. 63 / 192,927, filed on 25 May 2021, the contents of which are incorporated herein by reference in their entirety.

[0002] (Technical field) The present invention relates to injection-molded articles and methods for manufacturing the same. The injection-molded articles are helmet covers for protective helmets, and more specifically, replaceable helmet covers for improving the aesthetic appearance of helmets used in military, construction, manufacturing, and / or competitive sports such as American football, baseball, lacrosse, hockey, equestrian, skiing, and snowboarding. [Background technology]

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

[0004] Each helmet is uniquely molded to fit the user's head size, not only providing protection against specific impact risks associated with its intended use. Helmets often include internal cushioning and external hardware such as a face mask, chin strap, and decorative elements. In addition, helmets are designed to meet any specific safety requirements and regulations associated with their particular use.

[0005] Due to the various design and safety considerations associated with producing and manufacturing helmets, they are expensive safety equipment. As a result, players and other users are typically issued only one 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 new helmets limits the number of helmets issued to each user.

[0006] At the same time, users may wish to change the appearance of their uniforms for various reasons, including showcasing "retro" uniforms, supporting specific sports, honoring specific individuals or organizations, or celebrating specific achievements or involvement in notable competitions. 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 earlier, this is not an economic choice, and most organizations cannot afford to promote this option.

[0007] Helmets can be painted, covered with adhesive labels or patches, or covered with wrap or multi-piece covers. Each option has its drawbacks. For example, painting a helmet is time-consuming and expensive, and generally requires the presence of a trained individual to achieve a consistent appearance across all helmets. In addition, painted helmets generally cannot be returned to their original color unless repainted, which requires additional time and expense. Adhesive logos and stickers do not require a high level of skill, but the cost varies depending on the quality and size of the stickers. In addition, due to the size and contours of the helmet, the size and shape of the stickers are limited to ensure that the stickers can be applied without wrinkles, air holes, or creases, and as a result, it is impossible to change the overall appearance of the helmet using this method. Wraps and other multi-piece covers are difficult to install accurately, and if they are not applied correctly, they will have clearly visible seams. Some wraps are available as a single unit, while others also use adhesive or heat methods for application. Adhesive wraps are difficult to apply because the product can bend and adhere to itself, and the heating and bonding techniques are, again, expensive and time-consuming, requiring application by a professional.

[0008] In any of these applications, if the product is not applied with skill and precision, the final result may be visually unsatisfactory, with variations between helmets, wrinkles, creases, and improper orientation. [Overview of the project] [Means for solving the problem]

[0009] The present invention relates to injection-molded articles and methods for manufacturing the same. The injection-molded articles are helmet covers for protective helmets, and more specifically, replaceable helmet covers for improving the aesthetic appearance of helmets used in military, construction, manufacturing, and / or competitive sports such as American football, baseball, lacrosse, hockey, equestrian, skiing, and snowboarding.

[0010] The helmet covers according to this disclosure are formed from a single piece of molding and therefore require no assembly. Although formed from a single piece of molding, such helmet covers still maintain a comfortable fit that mimics the shape of large, irregular, and curved helmet forms used in athletic, industrial, and military applications. These helmet covers are designed to fit snugly onto a helmet and therefore can be applied without the use of adjustments or fasteners. Because such helmet covers are formed from a single piece of molding, they can be applied without visible seams, wrinkles, air vents, and / or folds. These helmet covers can be applied and removed quickly without requiring any skill and without damaging or altering the surface of the helmet. These helmet covers can be manufactured in a variety of colors and designs and may 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 make it possible for the helmet covers to be offered at an economical price, thereby increasing the number of times a team can change the design of its helmet covers.

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

[0012] The present invention also provides a method for manufacturing a helmet cover. The method provides a polymer injection unit comprising (A)(i) a barrel-mounted screw assembly, the barrel-mounted screw assembly comprising a screw mounted in a barrel; (ii) a processing space, the processing space comprising 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 comprising one or more nozzles located at the distal end of the processing space. The method for manufacturing a helmet further comprises (B) providing an injection mold tool, the injection mold tool comprising a mold cavity in fluid communication with one or more nozzles, and the injection mold tool is constructed to form a helmet cover in a single molding. The method for manufacturing a helmet further comprises (C) introducing a polymer material into the processing space. A method for manufacturing a helmet further comprises (D) melting a polymer material in a processing space, which is achieved by using a screw mounted in a barrel to mix the polymer material, applying a heat source to bring the polymer material to a first predetermined temperature and generate a predetermined back pressure. A method for manufacturing a helmet further comprises (E) injecting a certain volume of polymer material into a mold cavity through one or more nozzles, the volume of polymer material being sufficient to fill the mold cavity. A method for manufacturing a helmet further comprises (F) cooling the polymer material in the mold cavity to a second predetermined temperature. A method for manufacturing a helmet further comprises (G) extracting the polymer material in the mold cavity from an injection mold tool to provide a helmet cover.

[0013] A method of manufacturing a helmet cover may further optionally include providing an injection mold tool, which may 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 an injection mold tool using the helmet cover geometry file. Modifying the helmet geometry file may 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 micropores to the helmet cover. Additionally, adjusting the helmet cover geometry file may 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 single-piece shell assembly having a receiving cavity, an inner surface, and an outer surface, wherein the receiving cavity is configured such that the inner surface of the single-piece shell assembly contacts the outer surface of a helmet, and the single-piece shell assembly fits and is removable over the outer surface of the helmet. (Item 2) The helmet cover according to item 1, wherein the single-piece shell assembly covers the outer surface of the helmet in a adaptable and removable manner without the use of adjustable fasteners. (Item 3) The helmet cover according to item 1, further comprising a finishing layer, the finishing layer being bonded to the outer surface of the single-piece shell assembly. (Item 4) The helmet cover according to item 1, wherein the single shell assembly further comprises one or more openings through it, the one or more openings corresponding to one or more openings of the helmet. (Item 5) The helmet cover according to item 1, wherein the single-shell assembly further comprises a gripping member, the gripping member being snap-fitted to the outer edge of the outer surface of the protective helmet. (Item 6) The helmet cover according to item 1, wherein the single-piece shell assembly is made from injection-molded thermoplastic polyurethane (TPU) or thermoformed TPU. (Item 7) The helmet cover according to item 1, wherein the single-piece shell assembly is made from a material selected from the group consisting of TPU90, TPU95, and mixtures thereof. (Item 8) The helmet cover according to item 1, wherein the single-piece shell assembly is made of TPU and optionally one or more additives selected from the group consisting of coloring pigments, finishing surface chemicals, utility additives, and mixtures thereof. (Item 9) The helmet cover according to item 1, wherein the inner surface of the single-shell assembly is provided with a plurality of micropores. (Item 10) The helmet cover according to item 1, wherein the outer surface of the single-shell assembly has a plurality of micropores. (Item 11) The helmet cover according to item 1, wherein the single-shell assembly comprises a plurality of micropores, each of which independently has a diameter of approximately 1 μm ± 0.5 μm. (Item 12) The single-shell assembly comprises a plurality of micropores, the plurality of micropores having approximately 3.2 e7 micropores / cm². 2 A helmet cover as described in item 1, having the distribution of [specified distribution]. (Item 13) The single-piece shell assembly is a helmet cover as described in item 1, having a thickness of 0.25 mm to 4 mm. (Item 14) The single-shell assembly is the helmet cover described in item 1, having a thickness of 1 ± 0.1 mm. (Item 15) A method for manufacturing a helmet cover, wherein the method is A. To provide a polymer injection unit, wherein the polymer injection unit is (i) A barrel-mounted screw assembly comprising a screw mounted in a barrel, (ii) A processing space comprising a distal end and a proximal end, (iii) One or more nozzles that are in fluid communication with the processing space, wherein the one or more nozzles are located at the distal end of the processing space and It has the following characteristics: B. To provide an injection mold tool, wherein the injection mold tool comprises a mold cavity having fluid communication with one or more nozzles, and the injection mold tool is constructed to form the helmet cover in a single molding process. C. Introducing the polymer material into the processing space, D. Melting the polymer material in the processing space, wherein the melting is achieved 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 generating a predetermined back pressure. E. Injecting a certain volume of the polymer material into the mold cavity through one or more nozzles, wherein the volume of the polymer material is sufficient to fill the mold cavity. F. Cooling the polymer material in the mold cavity to a second predetermined temperature, G. Extracting the polymer material from the mold cavity using the injection mold tool and providing the helmet cover. Methods that include... (Item 16) The method according to item 15, wherein the polymer material is thermoplastic polyurethane (TPU). (Item 17) The method according to item 15, wherein the polymer material is selected from the group consisting of at least TPU90, TPU95, or mixtures thereof. (Item 18) The method according to item 15, wherein the polymer material is TPU and optionally one or more additives, the one or more additives being selected from the group consisting of coloring pigments, finishing surface chemicals, utility additives, and mixtures thereof. (Item 19) The helmet cover is made according to the method of item 15, having a thickness of 1 ± 0.1 mm. (Item 20) The method according to item 15, wherein the formwork cavity is formed to give a micro-hole on the helmet cover. (Item 21) The method for manufacturing the helmet cover according to item 15, further comprising extracting the polymer material from the mold cavity, and then giving microholes on the helmet cover via a mechanical process or a laser drilling process. (Item 22) The method according to item 15, wherein the mold cavity is formed to give micropores on the helmet cover, and the micropores have a diameter of approximately 1 μm ± 0.5 μm. (Item 23) The method according to item 15, wherein the first predetermined temperature is 230 ± 3°C. (Item 24) The method described in item 15, wherein the predetermined back pressure is 5 ± 1 bar. (Item 25) The method according to item 15, wherein the second predetermined temperature is 60±2℃. (Item 26) The method according to item 15, wherein the injection of the aforementioned volume of the polymer material is achieved by applying a first progressive pressure gradient, the progressive pressure gradient being approximately 70 bar to 15 bar. (Item 27) The method according to item 15, wherein the injection of the aforementioned volume of the polymer material occurs within 20 ± 5 seconds. (Item 28) The method according to item 15, wherein the cooling of the polymer material within the mold cavity occurs within 60 ± 5 seconds. (Item 29) The method according to item 15, wherein the steps of introducing the polymer material into the processing space, melting the polymer material in the processing space, injecting a certain volume of the polymer material into the mold cavity through one or more nozzles, and cooling the polymer material in the mold cavity occur within 130 ± 20 seconds. (Item 30) The method of item 15, further comprising injecting the aforementioned volume of the polymer material into the mold cavity through one or more nozzles, and holding the mold cavity at a holding pressure of 100 bar when the mold cavity is filled to 99% by volume. (Item 31) Providing injection formwork tools is, Scan the helmet and obtain the helmet's geometric shape file, Modify the aforementioned helmet geometric shape file to form a helmet cover geometric shape file, Printing a 3D helmet cover prototype, Adjusting the aforementioned helmet cover geometric shape file, Using the aforementioned helmet cover geometric shape file, the injection mold tool is generated. It further includes, Modifying the helmet geometric shape file includes 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 multiple microholes to the helmet cover, or one or more combinations thereof. The method according to item 15, which includes adjusting the helmet cover geometric shape file to provide an improved fit of the helmet cover compared to a three-dimensional helmet cover prototype. [Brief explanation of the drawing]

[0014] [Figure 1] Figure 1 illustrates a helmet cover positioned adjacent to a helmet according to one embodiment of the present disclosure.

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

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

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

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

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

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

[0021] [Figure 4] Figure 4 is an enlarged view of an exemplary helmet cover with a gripping member according to one embodiment of the present disclosure.

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

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

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

[0025] [Figure 8] Figure 8 illustrates an injection formwork tool according to one embodiment of the present disclosure.

[0026] [Figure 9] Figure 9 shows a method for providing an injection formwork tool according to one embodiment of the present disclosure. [Modes for carrying out the invention]

[0027] The present invention can be more readily understood by carefully reading the following detailed description of the invention and the study of the included examples.

[0028] As used herein, the following terms have the meanings they are deemed to belong to unless otherwise specified.

[0029] As used herein and in the claims, the terms “comprise,” “comprising,” “include,” “including,” and “includes” are intended to specify the presence of a material, substance, feature, integer, component, or step being described, 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," when determined by those skilled in the art, modifies the values ​​in question so that they fall within an acceptable margin of error, and this will depend in part on the limitations of the measurement system.

[0031] As used herein, the articles “a” and “an” mean “one or more” or “at least one” unless otherwise indicated. That is, any reference to an element or component of an embodiment using the indefinite article “a” or “an” does not exclude the possibility that there may be two or more elements or components.

[0032] As used herein, the term “helmet” refers to a protective head covering for use in any of a variety of applications, including sports, personal protective equipment (in construction or manufacture, etc.), military, or other uses. The term “helmet” is intended to include any type of helmet, including, but not limited to, helmets used in American football, baseball, lacrosse, hockey, equestrian, skiing, snowboarding, construction, military applications, etc. A suitable exemplary helmet currently on the market is provided in Example 1. Those skilled in the art will understand that these helmets may be modified over time by manufacturers and that new helmets may enter the market. Any similar helmet or future helmet model will be included within the meaning of this term.

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

[0034] As used herein, the term “unitary shell assembly” refers to any number of components formed integrally during a manufacturing process. In one non-limiting example, in one embodiment, a unitary shell assembly includes a receiving cavity, an inner surface, and an outer surface, all of which may be formed from the same thermoplastic, a mixture of thermoplastics, or a mixture of thermoplastics and one or more additives. In another non-limiting example, in one embodiment, a unitary shell assembly includes a receiving cavity, an inner surface, and an outer surface, all of which may be formed within a single mold cavity.

[0035] As used herein, the term "receiving cavity" refers to a space configured to receive an object having a given geometric shape. For example, in one embodiment, a receiving cavity may be configured to receive a helmet of any preferred shape and / or size.

[0036] As used herein, the term "interior surface" refers to a surface that faces inward from the user.

[0037] As used herein, the term “exterior surface” refers to a surface that faces outward from the user and includes any surface other than an interior surface. An exterior surface may have one or more outer edges that define the outer limit of the exterior surface.

[0038] As used herein, the terms “fitted” or “fittably” refer to a close, tight, or comfortable relationship between two objects. In some embodiments, a “fitted” relationship allows two objects to remain in contact in the absence of tensile force, with or without the assistance of fasteners or gripping members.

[0039] As used herein, the terms “detach” or “detachably” refer to the ability to separate two objects. In some embodiments, objects may be detached by the use of tensile force.

[0040] As used herein, the term “adjustable fastener” refers to a device for closing or securing an object that may be modified or moved in order 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] As used herein, the term “finish layer” refers to a surface layer applied to the inner or outer surface of a helmet cover. In some embodiments, the finish layer may include paints, powder coatings, graphics, thin film preparations, or a combination thereof. In some embodiments, the finish layer may be applied by painting, bead blasting, etching, UV curing, silkscreening, hydro dipping, physical vapor deposition, or a combination thereof.

[0042] As used herein, the terms “adhere,” “adheres,” or “adhered” refer to the bonding or creation of contact between two or more surfaces or materials through molecular interactions.

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

[0044] As used herein, the term “snappably attaches” refers to closing or fitting components into place through abrupt force without adjustment.

[0045] As used herein, the term “thermoplastic” refers to a certain class of polymers that become flexible or moldable at certain high temperatures and solid when cooled. 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 may be used depending on the application, including the desired physical attributes of the finished product. In some embodiments, the thermoplastic may be a recycled thermoplastic from waste products, discarded products, or other uses.

[0046] As used herein, the term “polymeric material” refers to an injection-molded substrate which may comprise one or more thermoplastics and, optionally, additional additives such as coloring pigments, glitters, finishing surface chemicals, utility additives, and mixtures thereof.

[0047] As used herein, the term “thermoplastic polyurethane” (“TPU”) refers to a type of thermoplastic plastic produced from a block copolymer consisting of alternating sequences of rigid (highly polar) domains and flexible (lowly polar) 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] TPU is available in several hardness grades, measured by the Shore A and / or Shore D values ​​of the TPU, which are determined according to ASTM D2240. TPU with hardness values ​​of approximately 10A to 50A is very soft, TPU with hardness values ​​of 50A to 80A is soft, TPU with hardness values ​​of 80A to 90A is medium, TPU with hardness values ​​of 90 to 95A is hard, and TPU with hardness values ​​of 60D to 75D is very hard. The term "TPU90" refers to TPU with a Shore A value of 90. The term "TPU95" refers to TPU with a Shore A value of 95.

[0049] Other defining properties of TPU or TPU mixtures include density (e.g., as measured by ASTM D792), tensile strength and elongation at break (e.g., as measured by ASTM D412), abrasion rate (e.g., as measured by ISO 4649), and tear strength (e.g., as measured by ASTM D624). The most suitable TPU or TPU mixture for a particular product will depend on the application, manufacturing method, and the 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 product. In embodiments of the present invention, any number of suitable additives may be used alone or in combination, provided that they achieve their intended purpose and do not adversely affect the performance characteristics of the helmet cover to a substantial degree. Exemplary additives include, but are not limited to, coloring pigments, finishing surface chemicals, utility additives, and mixtures thereof. Additives may be employed in any suitable amount, provided that, when present, they achieve their intended purpose and do not adversely affect the performance characteristics of the helmet cover to a substantial degree.

[0051] As used herein, the term “thickness” refers to the distance between opposite surfaces. For example, in one embodiment, the term “thickness” refers to the distance between the inner surface of a helmet cover and the outer surface of a helmet cover. While various thicknesses are disclosed, it should be understood that the process for manufacturing the articles is subject to natural process variations, and therefore reasonable differences from the desired thickness are within the scope of this disclosure. For example, whether the single-piece shell assembly described herein has one or more thicknesses, each of the one or more thicknesses would typically be between 0.25 mm and 4 mm.

[0052] As used herein, the term "up to" refers to a value less than the indicated value and greater than zero (i.e., it will not include the value of zero (0)). For example, in the reference herein to a single-body shell assembly having a thickness of up to 4 mm, the thickness will be less than 4 mm and greater than zero.

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

[0054] As used herein, the term “polymeric injection unit” refers to a unit operating part for melting polymer 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. A polymeric injection unit may also include a hopper assembly for introducing the polymer material into the processing space. In one embodiment, 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 polymer material before feeding. The polymeric injection unit may also include vents or ports for reducing the water and / or volatile moisture content of the polymer material.

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

[0056] As used herein, the term "processing space" refers to the hollow chamber within the polymer injection unit, where the barrel-mounted screw assembly operates.

[0057] As used herein, the term "nozzle" refers to a tubular section used to inject polymer material into an injection mold tool.

[0058] As used herein, the term "injection mold tool" refers to an assembly of parts that allows molten polymer material to be formed and cooled to produce separate manufactured products, such as helmet covers. An injection mold tool includes a mold cavity.

[0059] As used herein, the term “mold cavity” refers to the portion of an injection mold tool that, upon cooling, imparts the shape of the manufactured product to the molten polymer material. A mold cavity includes a hollow portion and a core portion, which together provide the shape of the manufactured product. In the manufacture of a helmet cover, the hollow portion of the mold cavity imparts the shape of the outer surface of the helmet cover, while the core portion imparts the shape of the inner surface of the helmet cover.

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

[0061] As used herein, the term “predefined” refers to a predetermined setpoint. For example, the term “predefined temperature” refers to a desired temperature setpoint. Another example is the term “predefined pressure” referring to a desired pressure setpoint. The predefined setpoint may be determined based on the specifications of the manufacturing process, such as the melting point of a polymer material. While various predefined setpoints are disclosed, it should be understood that the process for manufacturing the article is affected by variations in the setpoint, and therefore reasonable deviations from desired predefined values ​​are within the scope of this disclosure.

[0062] As used herein, the term “progressive gradient” refers to a set of predetermined variables that are modified in stages. For example, the term “progressive pressure gradient” refers to a set of predetermined pressures that are achieved in sequence. Various predetermined setpoints for progressive gradients are disclosed, but it should be understood that the process for manufacturing an article is affected by variations in the setpoints, and therefore reasonable deviations from a desired progressive gradient are within the scope of this disclosure.

[0063] As used herein, the term "back pressure" refers to the amount of pressure exerted by a polymer material on a barrel-mounted screw assembly during melting.

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

[0065] As used herein, the term "injecting" refers to the process of pushing molten polymer material through one or more nozzles into the mold cavity of an injection molding tool.

[0066] As used herein, the term "cooling" refers to the process of solidifying molten polymer material within the mold cavity of an injection molding tool.

[0067] As used herein, the term "extracting" refers to the process of removing cooled polymer material from the mold cavity of an injection mold tool in order to provide a desired manufactured product, such as a helmet cover. Extraction can be carried out manually, robotically, or using specialized tools.

[0068] The term "helmet geometry file" refers to a computerized model, such as a CAD representation, obtained from 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 the physical representation of a helmet cover geometric shape file obtained through 3D printing.

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

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

[0073] Referring to Figure 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 very similar to that of the helmet 102 and includes any helmet openings 104 and helmet fastening locations 106. For example, as shown in Figure 1-2, the helmet cover 100 includes one or more openings 108 corresponding to the helmet openings 104. Similarly, the helmet cover 100 includes one or more openings 108 corresponding to the helmet fastening locations 106.

[0074] As shown in Figure 1-2, the helmet cover 100 is sized to slide over the outer surface of the helmet 102 so as to fit snugly over the outer surface of the helmet 102. The fit between the helmet cover 100 and the helmet 102 is such that the helmet cover 102 cannot be removed from the helmet 100 without applying tensile force, while the helmet cover 100 can be removed from the helmet 102. Since the helmet cover 100 is formed to fit snugly over the outer surface of the helmet 102, adjustable fasteners are not required to achieve the desired fit between the helmet cover 100 and the helmet 102.

[0075] As shown in Figures 3A-E, the helmet cover 100 of the present invention includes a single-piece shell assembly 202. The single-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 substantially similar to the shape and size of the outer surface of the helmet 102.

[0076] The helmet cover 100 can be made from thermoplastic plastic, a mixture of thermoplastic plastics, or one or more thermoplastic plastics and one or more additives. Exemplary thermoplastic plastics 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 mixtures thereof. For example, the helmet cover 100 can be made from one or more TPUs. Exemplary additives include, but are not limited to, coloring pigments, finishing surface chemicals, utility additives, and mixtures thereof. In one embodiment, the helmet cover 100 is made from TPU90, TPU95, or a mixture thereof.

[0077] As shown in Figure 4, in one embodiment, the single-piece 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 to snap-fit ​​to the outer edge of the outer surface of the helmet 102 and thus can provide a secure and partially encircling fit with the outer edge. The gripping member 300 may be designed to accommodate all of the outer edges of the outer surface of the helmet 102, or it may be designed to accommodate only a certain outer edge of the outer surface of the helmet 102, the outer edge being selected according to the desired appearance of the helmet cover 100.

[0078] As shown in Figure 5, the helmet cover 100 may further include a finishing layer 400. A person skilled in the art will recognize any number of suitable finishing layers, and will understand that any such finishing layer may be used as long as it can withstand the applied forces and intended use. For example, the finishing layer 400 may include one or more of the following: paints, powder coatings, protective coatings, graphics, thin film preparations, or combinations thereof. The finishing layer 400 may be applied by painting, bead blasting, etching, UV curing, silkscreen, hydro dipping, physical vapor deposition, or other known application techniques.

[0079] The inner surface 204 and / or outer surface 206 of the helmet cover 100 may contain a plurality of micropores. When used on the inner surface 204 and / or outer surface 206, the plurality of micropores can improve the surface properties of the inner surface 204 and / or outer surface 206. For example, the micropores may alter the coefficient of friction experienced by the inner surface 204 and / or outer surface 206, or alter the porosity of the inner surface 204 and / or outer surface 206 to promote adhesion of the finish layer 400. The micropores may be introduced onto the inner surface 204 and / or outer surface 206 as part of the injection molding process, or by a mechanical or laser process after the injection molding is complete. The diameter, density, and location of the micropores may be varied to achieve the desired surface properties.

[0080] The helmet cover 100 of the present invention can generally be manufactured according to known methods for producing articles made from thermoplastic plastics, such as injection molding and thermoforming.

[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 polymer material, (604) melting the polymer material, (606) injecting the polymer material, (608) cooling the polymer material, (610) extracting the polymer material, and (612) providing the helmet cover.

[0082] As shown in Figure 7, in one embodiment, step 602: introducing the polymer material is achieved by feeding the 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 that are in fluid communication with both the processing space 704 and the 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 positioned in the processing space to support the conical hopper, and optionally a hopper heater and dryer for adjusting the moisture content of the polymer material before 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: While introducing the polymer material, the barrel-mounted screw assembly 702 rotates within the processing space 704, transporting the polymer material 710 through the processing space in a proximal-to-distal direction, thereby generating an axial (i.e., forward) motion of the polymer material through the interaction between the barrel-mounted screw assembly and the processing space.

[0084] Referring further to Figures 6 and 7, during step 604, i.e., while the polymer material is melting, the barrel-mounted screw assembly 702 and the outer limit of the processing space 704 (generally referred to as the barrel) interact to melt, transport, and apply pressure to the polymer material, thereby preparing the polymer material 710 for injection in step 606. To facilitate the interaction, the barrel of the processing space 704 may be partially or entirely grooved, depending on the application. Similarly, the length, diameter, and rotational speed of the barrel-mounted screw assembly 702 may be varied to obtain desired melting characteristics and consistent output. In one embodiment, the barrel-mounted screw assembly 702 may include one or more areas in which the diameter of the screw or the pitch of the helical channels may be varied to yield appropriate feed rate, compression, and measurement. The melting uniformity of the polymer material 710 may also be varied by predefining the force generated by the barrel-mounted screw 702, also referred to as back pressure.

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

[0086] When two or more barrel sections 712 are included in the processing space, generally, the barrel section 712 on the proximal end (712a) of the processing space has a lowest temperature setpoint to prevent premature melting and crosslinking during step 602: introducing the polymer material. The temperature of the remaining barrel sections 712 can then be varied in the direction progressing from the proximal end to the distal end of the processing space, for example, by increasing the barrel section temperature setpoint in the distal direction. In this manner, the temperature setpoint increases as it moves through 712a, 712b, 712c, and 712d. For example, in one embodiment, the temperature setpoint may be 200±5°C with respect to barrel section 712a, 215±5°C with respect to barrel section 712b, 225±5°C with respect to barrel section 712c, and 230±5°C with respect to barrel section 712d.

[0087] As also shown in Figures 6 and 7, during step 606: Injecting the polymer material, the polymer material 710 is pushed through one or more nozzles 706 and introduced into the injection mold tool 800. As shown in Figure 8, in one embodiment, the 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 injector pin 826, an injector plate 828, and a clamp plate 830. The mold cavity 812 includes one or more cavity portions 814 and a core portion 816.

[0088] Referring further to Figure 6-8, when the injection molding method 600 is performed, one or more nozzles 706, sprue bushings 804, and runners 824 are in communication, thereby allowing the polymer material 710 to be pushed from the processing space 704 into the mold cavity 812 and fill the mold cavity 812. In one embodiment, during step 606: injecting the polymer material, the mold cavity 812 is filled in two stages, referred to as the filling / packing stage and the holding stage.

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

[0090] During the holding phase, the molten polymer material 710 is held at a specific holding pressure until no more polymer material 710 flows into the mold cavity 812. The holding pressure may be varied depending on the processing specifications of the polymer material 710 and may be a pressure gradient. The holding pressure is applied when the mold cavity 812 is filled to approximately 90-99% by volume.

[0091] Looking again at Figure 6, during step 608: cooling the polymer material, the polymer 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 polymer material 710. The second predetermined temperature can be achieved by cooling the cavity portion 814 and the core portion 816 to a specific temperature setpoint. The temperature setpoints for the cavity portion 814 and the core portion 816 may be the same or different depending on the process. For example, the temperature setpoints for the cavity portion 814 and the core portion 816 may be within the range of 60°C ± 10°C.

[0092] Continuing to refer to Figure 6, step 610: While the polymer material is being extracted, 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 achieved by manual extraction using the injection pin 826 and the injection plate 828, or both. Finally, during step 612, i.e., while providing the helmet cover, the helmet cover 100 is provided according to the embodiments described herein.

[0093] As shown in Figure 9, the injection formwork tool 800 may be designed and provided through a method for providing the tool 900. In one embodiment, the method for providing the tool 900 includes (902) scanning the helmet 102 to obtain a helmet geometric shape file, (904) modifying the helmet geometric shape file to form a helmet cover geometric shape file, (906) printing a three-dimensional helmet cover prototype from the helmet cover geometric shape file, (908) adjusting the helmet cover geometric shape file, and (910) generating the injection formwork tool 800 using the helmet cover geometric shape file.

[0094] During step 902, i.e., scanning the helmet 102 to obtain a helmet geometric shape 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 geometric shape file can be generated by scanning the helmet 102, obtaining relevant surface measurements, and generating a CAD model using known methods of surface measurement and surface data output. These methods include the step of 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 required for each pulse to reflect back to the scanner, and using these time measurements to determine the precise location of points on the scanned object. Mesh data is obtained by subdividing the surface structure into sets of polygons, which divide a continuous surface into vertices, edges, and faces, and these vertices, edges, and faces may be represented in the computerized model.

[0095] Step 904: While modifying the helmet geometry file to form the helmet cover geometry file, the helmet geometry file is manipulated to generate the helmet cover geometry file. Modifications may include manipulating the size, shape, and / or structure of the helmet 102 as depicted in the geometry file. Modifications may also 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 multiple microholes to the helmet geometry file, or a combination thereof. The file resulting from modifications applied to the helmet geometry file is referred to as the helmet cover geometry file.

[0096] For example, during step 904: modifying the helmet geometric shape file to form the helmet cover geometric shape file, the helmet geometric shape file can be modified by manipulating the size and shape of the helmet 102 depicted in the helmet geometric shape file to obtain the helmet cover geometric shape file. To manipulate the size, the helmet geometric shape 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 geometric shape file is then machined the inner surface depicted in the helmet geometric shape file, thereby modifying 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 geometric shape file in this manner to generate the helmet cover geometric shape file allows the finished helmet cover 100 to slide on top of the helmet 102 rather than "stack" on top of it. The manipulation of specific types of sizes and shapes also preserves the helmet-like shape of the helmet cover 100, ensuring that the helmet cover 100 comfortably covers and fits the helmet 102 despite the large and irregular shapes of both the helmet cover 102 and the helmet 100. Additional modifications, such as adding one or more openings to the helmet geometric shape file, adding one or more gripping members to the helmet geometric shape file, adding multiple microholes to the helmet geometric shape file, or a combination thereof, may then be made to the helmet geometric shape file. The final product of the modifications is the helmet cover geometric shape file.

[0097] During step 906, i.e., printing the 3D helmet cover prototype from the helmet cover geometric shape file, a 3D helmet cover prototype corresponding to the helmet cover geometric shape file is provided. The 3D helmet cover prototype allows the manufacturer to inspect the fit of the 3D helmet cover prototype when it is applied to the helmet 102 and to focus on any areas where adjustment is required. During step 908: adjusting the helmet cover geometric shape file, the helmet cover geometric shape file is adjusted to provide an improved fit of the helmet cover 100 compared to the 3D helmet cover prototype. Steps 906: printing the 3D helmet cover prototype from the helmet cover geometric shape file and step 908: adjusting the helmet cover geometric shape file may 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 geometric shape file are achieved, step 910 is performed: generating an injection mold tool 800 using the helmet cover geometric shape file. The injection mold tool 800 is designed to provide the desired helmet cover 100, while also adapting to the required process attributes such as injection flow rate, removal of molded articles, temperature and pressure control. The injection mold tool is designed according to the description herein.

[0099] (Embodiment) (Helmet cover) Aspects of the present invention relate to a helmet cover made from a single-piece shell assembly comprising a receiving cavity, an inner surface, and an outer surface. The receiving cavity is configured such that the inner surface of the single-piece shell assembly contacts the outer surface of the helmet. The single-piece shell assembly covers the outer surface of the helmet in a adaptable and removable manner.

[0100] Another aspect of the present invention relates to a helmet cover comprising a single-piece shell assembly. The single-piece shell assembly comprises 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 single-piece shell assembly contacts the outer surface of the helmet. The single-piece shell assembly fits and is removablely covered over the outer surface of the helmet and is snap-fitted to the outer edge of the outer surface of the helmet via the use of the gripping member.

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

[0102] In various embodiments, a single-piece shell assembly covers the outer surface of the helmet in a adaptable and removable manner without the use of adjustable fasteners.

[0103] In various embodiments, the helmet cover also includes a finishing layer that is bonded to the outer surface of the single-piece shell assembly. The finishing 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 method of manufacture. In some embodiments, the finishing layer includes paints, powder coatings, graphics, thin film preparations, or combinations thereof. The finishing layer may be applied by painting, bead blasting, etching, UV curing, silkscreening, hydro dipping, physical vapor deposition, or a combination thereof.

[0104] In various embodiments, a single-shell assembly further includes one or more openings through it. These one or more openings may correspond to one or more openings in a helmet. In some embodiments, these one or more openings provide access to various helmet features.

[0105] In various embodiments, the single-shell assembly further includes a gripping member. In one embodiment, the gripping member is snap-fitted to the outer edge of the outer surface of the helmet and thus provides a secure and partially enclosing fit with the outer edge. The gripping member is formed to provide a lip that is sized to accommodate the outer edge of the outer surface of the helmet. The gripping member may be designed to accommodate all of the outer edges of the outer surface of the helmet, or it may be designed to accommodate only a part of the outer edge of the outer surface of the helmet, the outer edge being selected according to the desired appearance and fit of the helmet cover.

[0106] In various embodiments, a single-shell assembly is made from a thermoplastic. In some embodiments, the thermoplastic is formed by 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, a single-shell assembly may be made from one or more TPUs. In some embodiments, the TPU is TPU90, TPU95, or a mixture thereof.

[0107] In various embodiments, a single-piece shell assembly is made from a thermoplastic and one or more additives. The one or more additives may include any suitable additives or mixtures of additives, provided that the additives do not interfere with desired attributes of the helmet cover, such as fit, ability to apply finish, durability of the finish, or method of manufacture. In some embodiments, the one or more additives may include coloring pigments, glitter, finishing surface chemicals, utility additives, and mixtures thereof. In some embodiments, the utility additives may include graphite, micro-vacuum spheres, or mixtures thereof.

[0108] In specific embodiments, the inner surface and / or outer surface of a single-shell assembly include a plurality of micropores. The plurality of micropores are positioned and sized to facilitate the insertion of a protective helmet. For example, in one embodiment, the plurality of micropores are positioned and sized to facilitate the adhesion of a finishing layer present on the outer surface of the single-shell assembly. The plurality of micropores may cover all or part of the inner surface and / or outer surface of the single-shell assembly. In one embodiment, the plurality of micropores preferably each independently have a diameter of 0.1 μm to 10 μm. In one embodiment, the plurality of micropores preferably each independently have a diameter of 0.5 μm to 5 μm. In one embodiment, the plurality of micropores preferably each independently have a diameter of about 1 μm ± 0.5 μm. In one embodiment, the plurality of micropores are 3.2e9 to 3.2e5 micropores / cm 2 It has the following distribution. In one embodiment, the number of micropores is 1.3e8 to 1.3e6 micropores / cm 2 It has a distribution of approximately 3.2 e7 micropores / cm². In one embodiment, the number of micropores is approximately 3.2 e7 micropores / cm². 2 It has the distribution of .

[0109] As a manufactured product, a single-piece shell assembly of a helmet cover will have a certain thickness. Within a single-piece shell assembly, the thickness may vary from section to section, or it may be consistent throughout. Regardless of whether the single-piece shell assembly is of a single thickness or multiple thicknesses, 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. More 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. 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 exceed 0.25 mm. For example, each of the one or more thicknesses may exceed 0.5 mm. More specifically, each of the one or more thicknesses may exceed 0.75 mm. More specifically, each of the one or more thicknesses may exceed 1 mm.

[0111] In one embodiment, the single-shell assembly has a thickness of 1 mm ± 0.75 mm. In one embodiment, the single-shell assembly has a thickness of 1 mm ± 0.5 mm. In one embodiment, the single-shell assembly has a thickness of 1 mm ± 0.25 mm. In one embodiment, the single-shell assembly has a thickness of 1 mm ± 0.2 mm. In one embodiment, the single-shell assembly has a thickness of 1 mm ± 0.15 mm. In one embodiment, the single-shell assembly has a thickness of 1 mm ± 0.1 mm. In one embodiment, the single-shell assembly has a thickness of 1 mm ± 0.09 mm. In one embodiment, the single-shell assembly has a thickness of 1 mm ± 0.08 mm. In one embodiment, the single-shell assembly has a thickness of 1 mm ± 0.07 mm. In one embodiment, the single-shell assembly has a thickness of 1 mm ± 0.06 mm. In one embodiment, the single-shell assembly has a thickness of 1 mm ± 0.05 mm. In one embodiment, the single-shell assembly has a thickness of 1 mm ± 0.04 mm. In one embodiment, the single-shell assembly has a thickness of 1 mm ± 0.03 mm. In another embodiment, the single-shell assembly has a thickness of 1 mm ± 0.02 mm. In yet another embodiment, the single-shell assembly has a thickness of 1 mm ± 0.01 mm. In yet another embodiment, the single-shell assembly has a thickness of approximately 1 mm.

[0112] (How to manufacture helmet covers) Another aspect of the present invention is a method for manufacturing a helmet cover, the method comprising: providing a polymer injection unit in a processing space; providing an injection molding tool having a mold cavity; introducing a polymer material into the processing space; melting the polymer material in the processing space; injecting a certain volume of the polymer material into the mold cavity of the injection molding tool; cooling the polymer material in 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 a helmet cover.

[0113] Another aspect of the present invention is a method for manufacturing a helmet cover. This method includes providing a polymer injection unit, providing an injection mold tool, introducing a polymer material into a processing space, melting the polymer material in the processing space, injecting a certain 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 located at the distal end of the processing space that are in fluid communication with the processing space. The polymer material is melted in the processing space by using a screw mounted in the barrel to mix the polymer material, applying a heat source to bring the polymer material to a predetermined temperature, and generating a predetermined back pressure. Once melted, the polymer material is injected into an injection mold tool through one or more nozzles.

[0115] The injection mold tool includes one or more nozzles and a mold cavity in fluid communication, and is constructed to form a helmet cover in a single molding process. 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. Once cooled, 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 an injection mold tool, a helmet is scanned to obtain a helmet geometric shape file. The helmet geometric shape file is modified to form a helmet cover geometric shape file. Modifying the helmet geometric shape file may include one or more of the following: 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 multiple microholes to the helmet cover. Using the helmet cover geometric shape file, a helmet cover prototype is generated via 3D printing. Based on the fit of the helmet cover prototype, the helmet cover geometric shape file is adjusted to provide an improved fit of the helmet cover compared to the 3D helmet cover prototype. Prototyping and adjustment are repeated until the desired fit and design for the helmet cover is achieved, and then an injection mold tool is generated using the helmet cover geometric shape file.

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

[0118] In various embodiments, the polymer material includes thermoplastics. In some embodiments, the polymer material includes thermoplastics 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 mixtures thereof. For example, the polymer material may include one or more TPUs. In some embodiments, the TPU is TPU90, TPU95, or a mixture thereof.

[0119] In various embodiments, the polymer material comprises a thermoplastic and one or more additives. The one or more additives may include any suitable additives or mixtures of additives, provided that the additives do not interfere with the desired attributes of the helmet cover, such as fit, ability to apply a finish, durability of the finish, or method of manufacture. In some embodiments, the one or more additives may include coloring pigments, glitter, finishing surface chemicals, utility additives, and mixtures thereof. In some embodiments, the utility additives may include graphite, micro vacuum spheres, or mixtures thereof.

[0120] In various embodiments, a method for manufacturing a helmet cover further includes providing micropores on the helmet cover. In one embodiment, a mold cavity is formed to provide micropores on the helmet cover. In one embodiment, providing micropores on the helmet cover is achieved via a mechanical or laser drilling process after the polymer material has been extracted from the mold cavity. The micropores are positioned and sized to facilitate the insertion of a protective helmet. For example, in one embodiment, the micropores are positioned and sized to facilitate the adhesion of a finishing layer present on the outer surface of a single-piece shell assembly. The micropores may cover all or part of the inner surface and / or outer surface of the single-piece shell assembly. In one embodiment, a method for manufacturing a helmet cover further includes providing micropores having a diameter of 0.1 μm to 10 μm. In one embodiment, a method for manufacturing a helmet cover further includes providing micropores having a diameter of 0.5 μm to 5 μm. In one embodiment, a method for manufacturing a helmet cover further includes providing micropores having a diameter of 1 μm to ±0.5 μm. In one embodiment, a method for manufacturing a helmet cover is such that the micropores are 3.2e9~3.2e5 cm². 2 The method further includes providing micropores having a distribution of 1.3e8-1.3e6 micropores / cm². In one embodiment, a method for manufacturing a helmet cover is provided. 2 The method further includes providing micropores having a distribution of approximately 3.2 e7 micropores / cm². In one embodiment, the method for manufacturing a helmet cover is to provide micropores having a distribution of approximately 3.2 e7 micropores / cm². 2 The method further includes providing micropores having a distribution of [value]. In various embodiments, the micropores may cover all or part of the inner surface of the single-shell assembly, the outer surface of the single-shell assembly, or both.

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

[0122] In various embodiments, a method for manufacturing a helmet cover includes generating a predetermined back pressure while melting a polymer material in a processing space. In one embodiment, the predetermined back pressure is less than about 20 bar. In another embodiment, the predetermined back pressure is less than about 15 bar. In yet another embodiment, the predetermined back pressure is less than about 10 bar. In yet another embodiment, the predetermined back pressure is 5 ± 1 bar.

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

[0124] In various embodiments, a method for manufacturing a helmet cover involves injecting a certain volume of polymer material, which is achieved by applying a first progressive pressure gradient. In one embodiment, the progressive pressure gradient is about 80 bar to about 10 bar. In another embodiment, the progressive pressure gradient is about 70 bar to about 15 bar.

[0125] In various embodiments, the injection of a certain volume of polymer material occurs within 20 ± 20 seconds. In some embodiments, the injection of a certain volume of polymer material occurs within 20 ± 15 seconds. In some embodiments, the injection of a certain volume of polymer material occurs within 20 ± 10 seconds. In some embodiments, the injection of a certain volume of polymer material occurs within 20 ± 5 seconds.

[0126] In various embodiments, cooling of the polymer material in the mold cavity occurs within 60 ± 20 seconds. In one embodiment, cooling of the polymer material in the mold cavity occurs within 60 ± 15 seconds. In another embodiment, cooling of the polymer material in the mold cavity occurs within 60 ± 10 seconds. In yet another embodiment, cooling of the polymer material in the mold cavity occurs within 60 ± 5 seconds.

[0127] In various embodiments, the process of introducing the polymer material into the processing space, melting the polymer material within the processing space, injecting a certain volume of the polymer material into the mold cavity through one or more nozzles, and cooling the polymer material within the mold cavity occurs within 130 ± 40 seconds. In one embodiment, the process of melting the polymer material within the processing space, injecting a certain volume of the polymer material into the mold cavity through one or more nozzles, and cooling the polymer material within the mold cavity occurs within 130 ± 30 seconds. In another embodiment, the process of melting the polymer material within the processing space, injecting a certain volume of the polymer material into the mold cavity through one or more nozzles, and cooling the polymer material within the mold cavity occurs within 130 ± 20 seconds. In yet another embodiment, the process of melting the polymer material within the processing space, injecting a certain volume of the polymer material into the mold cavity through one or more nozzles, and cooling the polymer material within the mold cavity occurs within 130 ± 10 seconds.

[0128] In various embodiments, injecting a certain volume of polymer material into a mold cavity through one or more nozzles further includes holding the mold cavity with a holding pressure when the mold cavity is filled to about 90–99% 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 with a holding pressure occurs when the mold cavity is filled to about 95–99% by volume. In some embodiments, holding the mold cavity with a holding pressure occurs when the mold cavity is filled to about 99% by volume.

[0129] (Enumerated embodiments) The specific embodiments 1–70 provided below are for illustrative purposes only and do not otherwise limit the scope of the subject matter disclosed as defined by the claims. These enumerated embodiments encompass all combinations, secondary combinations, and combinations that are referenced in combination (e.g., complexly dependent) described herein.

[0130] (Listed embodiments relating to helmet covers) Embodiment 1: A helmet cover comprising a single-piece shell assembly including a receiving cavity, an inner surface, and an outer surface, wherein the receiving cavity is configured such that the inner surface of the single-piece shell assembly contacts the outer surface of the helmet, and the single-piece shell assembly covers the outer surface of the helmet in a adaptable and removable manner.

[0131] Embodiment 2: The helmet cover according to Embodiment 1, wherein a single-piece shell assembly can adaptably and detachably cover the outer surface of a helmet without the use of adjustable fasteners.

[0132] Embodiment 3: The helmet cover according to Embodiment 1, further comprising a finishing layer bonded to the outer surface of a single-piece shell assembly.

[0133] Embodiment 4: A single-piece shell assembly further includes one or more openings through it corresponding to one or more openings of the helmet, in addition to any one of Embodiments 1-3. Helmet cover.

[0134] Embodiment 5: A helmet cover according to any one of Embodiments 1-4, wherein the single-shell assembly further includes a gripping member.

[0135] Embodiment 6: The helmet cover according to Embodiment 5, wherein the gripping member is snap-fitted 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 single-piece shell assembly is made from thermoplastic plastic.

[0137] Embodiment 8: The helmet cover according to 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: The helmet cover according to Embodiment 8, wherein the thermoplastic plastic is TPU.

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

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

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

[0142] Embodiment 13: A helmet cover according to any one of Embodiments 7-12, wherein the single-piece shell assembly is made from thermoplastic, and the thermoplastic includes recycled thermoplastic from waste products and / or discarded products.

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

[0144] Embodiment 15: The helmet cover according to Embodiment 14, wherein one or more additives include coloring pigments, glitter, finishing surface chemicals, utility additives, and mixtures thereof.

[0145] Embodiment 16: The inner surface of a single-shell assembly, the outer surface of a single-shell assembly, or both, includes a plurality of micropores, as described in any one of Embodiments 1-15. Helmet cover.

[0146] Embodiment 17: The helmet cover according to Embodiment 16, wherein the plurality of micropores are applied to less than the entire inner surface of a single shell assembly, less than the entire outer surface of a single shell assembly, or both.

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

[0148] Embodiment 19: Each of the plurality of micropores independently has a diameter of about 0.5 μm to 5 μm, and the helmet cover according to any one of Embodiments 16-18.

[0149] Embodiment 20: Each of the plurality of micropores independently has a diameter of about 1 μm ± 0.5 μm, and the helmet cover according to any one of Embodiments 16-19.

[0150] Embodiment 21: The plurality of micropores have an average diameter of 0.1 μm to 10 μm, and the helmet cover according to any one of Embodiments 16-20.

[0151] Embodiment 22: The plurality of micropores have an average diameter of 0.5 μm to 5 μm, and the helmet cover according to any one of Embodiments 16-21.

[0152] Embodiment 23: The plurality of micropores have an average diameter of about 1 μm ± 0.5 μm, and the helmet cover according to any one of Embodiments 16-22.

[0153] Embodiment 24: The plurality of micropores have a distribution of 3.2e9 to 3.2e5 micropores / cm 2 and the helmet cover according to any one of Embodiments 16-23.

[0154] Embodiment 25: The plurality of micropores have a distribution of 1.3e8 to 1.3e6 micropores / cm 2 and the helmet cover according to any one of Embodiments 16-24.

[0155] Embodiment 26: The plurality of micropores have a distribution of about 3.2e7 micropores / cm 2 and the helmet cover according to any one of Embodiments 16-25.

[0156] Embodiment 27: The single-body shell assembly has a thickness of 0.25 mm to 4 mm, and the helmet cover according to any one of Embodiments 1-26.

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

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

[0159] (Enumerated embodiments of methods for manufacturing helmet covers) Embodiment 30: A method for manufacturing a helmet cover, wherein the method is A. To provide a polymer injection unit, the polymer injection unit is (i) A barrel-mounted screw assembly, the barrel-mounted screw assembly includes a screw mounted in a barrel, (ii) A processing space, the processing space includes a distal end and a proximal end, (iii) One or more nozzles that are in fluid communication with the processing space, the one or more nozzles being located at the distal end of the processing space and The fact that it involves, B. To provide an injection mold tool, wherein the injection mold tool includes a mold cavity in fluid communication with a nozzle, and the injection mold tool is constructed to form a helmet cover in a single molding process. C. Introducing polymer materials into the processing space, D. The process involves melting a polymer material in a processing space, which is achieved by using a screw mounted in a barrel to mix the polymer material, applying a heat source, bringing the polymer material to a first predetermined temperature, and generating a predetermined back pressure. E. Injecting a certain volume of polymer material into a mold cavity through one or more nozzles, wherein the volume of polymer material is sufficient to fill the mold cavity. F. Cooling the polymer material inside the mold cavity to a second predetermined temperature, G. Extract polymer material from the mold cavity using an injection mold tool to provide a helmet cover. Methods that include...

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

[0161] Embodiment 32: A method for manufacturing a helmet cover, further comprising providing micro-holes on the helmet cover, according to any one of Embodiments 30-31.

[0162] Embodiment 33: The method according to Embodiment 32, wherein the micropores are applied to less than the entire inner surface of a single shell assembly, less than the entire outer surface of a single shell assembly, or both.

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

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

[0165] Embodiment 36: The method according to any one of Embodiments 32-35, wherein each micropore independently has a diameter of about 1 μm ± 0.5 μm.

[0166] Embodiment 37: The method according to 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 according to 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 according to any one of Embodiments 32-38, wherein the micropores have an average diameter of approximately 1 μm ± 0.5 μm.

[0169] Embodiment 40: The number of micropores is 3.2e9 to 3.2e5 micropores / cm². 2 The method according to any one of embodiments 32-39, having the distribution of .

[0170] Embodiment 41: The number of micropores is 1.3e8 to 1.3e6 micropores / cm². 2 The method according to any one of embodiments 32-40, having the distribution of .

[0171] Embodiment 42: The number of micropores is approximately 3.2 e7 micropores / cm². 2 The method according to any one of embodiments 32-41, having the distribution of .

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

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

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

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

[0176] Embodiment 47: The method according to any one of Embodiments 43-46, wherein the first predetermined temperature is 230±5℃.

[0177] Embodiment 48: A method for manufacturing a helmet cover, comprising generating a predetermined back pressure while melting a polymer material in a processing space, according to any one of Embodiments 30-47.

[0178] Embodiment 49: The method according to Embodiment 48, wherein the predetermined back pressure is less than approximately 20 bar.

[0179] Embodiment 50: The method according to any one of Embodiments 48-49, wherein the predetermined back pressure is less than approximately 15 bar.

[0180] Embodiment 51: The method according to any one of Embodiments 48-50, wherein the predetermined back pressure is approximately 5 ± 1 bar.

[0181] Embodiment 52: A method for manufacturing a helmet cover, comprising cooling the polymer material in the mold cavity to a second predetermined temperature, according to any one of Embodiments 30-51.

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

[0183] Embodiment 54: The method according to any one of Embodiments 52-53, wherein the second predetermined temperature is 60±8℃.

[0184] Embodiment 55: The method according to any one of Embodiments 52-54, wherein the second predetermined temperature is 60±6℃.

[0185] Embodiment 56: The method according to any one of Embodiments 52-55, wherein the second predetermined temperature is 60±4℃.

[0186] Embodiment 57: The method according to any one of Embodiments 52-56, wherein the second predetermined temperature is 60±2℃.

[0187] Embodiment 58: A method for manufacturing a helmet cover, comprising injecting a certain volume of polymer material, according to any one of Embodiments 30-57.

[0188] Embodiment 59: The method according to Embodiment 58, wherein the injection of a certain volume of polymer material is achieved by applying a first progressive pressure gradient.

[0189] Embodiment 60: The method according to Embodiment 59, wherein the progressive pressure gradient is approximately 80 bar to approximately 10 bar.

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

[0191] Embodiment 62: The method according to any one of Embodiments 58-61, wherein the injection of a certain volume of polymer material occurs within 20 ± 20 seconds.

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

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

[0194] Embodiment 65: The method according to any one of Embodiments 58-64, further comprising injecting a certain volume of polymer material into a mold cavity through one or more nozzles, and then holding the mold cavity at a certain holding pressure when the mold cavity is filled to about 90-99% by volume.

[0195] Embodiment 66: The method according to any one of Embodiments 58-65, further comprising injecting a certain volume of polymer material into a mold cavity through one or more nozzles, and holding the mold cavity at a certain holding pressure when the mold cavity is filled to about 95-99% by volume.

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

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

[0198] Embodiment 69: The method according to any one of Embodiments 30-68, wherein the polymer material includes a thermoplastic as described in any one of Embodiments 7-13.

[0199] Embodiment 70: The method according to any one of Embodiments 30-69, wherein the polymer material comprises a thermoplastic plastic as described in any one of Embodiments 7-13 and one or more additives as described in any one of Embodiments 14-15.

[0200] (Examples) (Example 1) The following table provides an exemplary commercially available helmet 102, and the helmet cover 100 can be positioned to cover the helmet 102. [Table 1-1] [Table 1-2] [Table 1-3]

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

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

Claims

1. A method for manufacturing a helmet cover, wherein the method is A. To provide a polymer injection unit, wherein the polymer injection unit is (i) A barrel-mounted screw assembly comprising a screw mounted in a barrel, (ii) A processing space comprising a distal end and a proximal end, (iii) One or more nozzles that are in fluid communication with the processing space, wherein the one or more nozzles are located at the distal end of the processing space and To be equipped with, B. To provide an injection mold tool, wherein the injection mold tool comprises a mold cavity having fluid communication with one or more nozzles, and the injection mold tool is constructed to form the helmet cover by integral molding, and to provide the injection mold tool, (i) Obtain a helmet geometric shape file by scanning the helmet, (ii) To form a helmet cover geometric shape file by modifying the helmet geometric shape file, (iii) Printing a 3D helmet cover prototype, (iv) Adjusting the helmet cover geometric shape file, (v) Using the helmet cover geometric shape file, generate the injection mold tool. Includes, Modifying the helmet geometric shape file includes 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 multiple micro-holes to the helmet cover, or one or more combinations thereof. Adjusting the helmet cover geometric shape file includes providing an improved fit of the helmet cover compared to the three-dimensional helmet cover prototype. C. Introducing the polymer material into the processing space, D. Melting the polymer material in the processing space, wherein the melting is achieved by mixing the polymer material using the screw mounted in the barrel and by applying a heat source to bring the polymer material to a first predetermined temperature and generate a predetermined back pressure. E. Injecting a certain volume of the polymer material into the mold cavity through one or more nozzles, wherein the volume of the polymer material is sufficient to fill the mold cavity. F. Cooling the polymer material in the mold cavity to a second predetermined temperature, G. To provide the helmet cover by extracting the polymer material from the mold cavity using the injection mold tool. Methods that include...

2. The method according to claim 1, wherein the polymer material is thermoplastic polyurethane (TPU).

3. The method according to claim 1, wherein the polymer material is selected from the group consisting of at least TPU90, TPU95, or a mixture thereof.

4. The method according to claim 1, wherein the polymer material is TPU.

5. The method according to claim 4, wherein the polymer material comprises one or more additives, the one or more additives being selected from the group consisting of coloring pigments, finishing surface chemicals, utility additives, and mixtures thereof.

6. The method according to claim 1, wherein the helmet cover has a thickness of 1 ± 0.1 mm.

7. The method according to claim 1, wherein the formwork cavity is formed to provide micro-holes on the helmet cover.

8. The method for manufacturing the helmet cover, further comprising extracting the polymer material from the mold cavity, and then providing micropores on the helmet cover via a mechanical process or a laser drilling process.

9. The method according to claim 1, wherein the formwork cavity is formed to give micropores on the helmet cover, and the micropores have diameters of 1 μm and 0.5 μm.

10. The method according to claim 1, wherein the first predetermined temperature is 230 ± 3°C.

11. The method according to claim 1, wherein the predetermined back pressure is 5 ± 1 bar.

12. The method according to claim 1, wherein the second predetermined temperature is 60 ± 2°C.

13. The method according to claim 1, wherein the injection of the aforementioned volume of the polymer material is achieved by applying a first progressive pressure gradient, the progressive pressure gradient being 70 bar to 15 bar.

14. The method according to claim 1, wherein the injection of the polymer material in the volume occurs within 20 ± 5 seconds.

15. The method according to claim 1, wherein the cooling of the polymer material within the mold cavity occurs within 60 ± 5 seconds.

16. The method according to claim 1, wherein the steps of introducing the polymer material into the processing space, melting the polymer material in the processing space, injecting the volume of the polymer material into the mold cavity through one or more nozzles, and cooling the polymer material in the mold cavity occur within 130 ± 20 seconds.

17. The method according to claim 1, further comprising injecting the polymer material in the aforementioned volume into the mold cavity through one or more nozzles, and holding the mold cavity at a holding pressure of 100 bar when the mold cavity is filled to 99% by volume.

Images