Inflatable protection device and method for manufacturing the same

Abstract

An inflatable protection device comprising a first layer and a second layer is described. The first layer and the second layer have a congruent outer contour along which the two layers are connected by means of a first connection to form an inflatable structure (10) which encloses a gas space. The inflatable structure has a plurality of protruding areas of a first type (20, 21, 22, 23, 23', 22', 21') being separated by non-inflatable areas (30), such that neighbored protruding areas of the first type (20, 21, 22, 23, 23', 22', 21') each have a border section of a first type (20, 21a; 21b, 22a; 22b, 23a;... ) being neighbored to each other, such that they define a pair of border sections of a first type (20b, 21a; 21b, 22a;...). The border sections of the first type defining a pair of border sections of the first type are connected by means of a shaping connection of a first type that reduces the area of its allocated non-inflatable area. When the inflatable protection device is inflated to form an inflated protection device, the outer surface of the first layer has an overall concave shape and the outer surface of the second layer has an overall convex shape.

Description

[0001] Inflatable protection device and method for manufacturing the same

[0002] Description

[0003] The invention relates to an inflatable protection device according to claim 1 and to a method for producing such an inflatable protection device according to claim 14.

[0004] Protection devices for a body part of a human play an important role for the safety of a human during various activities, for example riding, bicycle riding, motorcycle riding, climbing, skiing, and many others. A key protection device for such activities is a helmet. Since the invention relates in the first place to helmets, reference is in the following mainly made to these kinds of a protection devices, but it needs to be mentioned that the invention is not limited to helmets, as will be seen later.

[0005] A helmet always comprises a main part which is adapted for covering at least a part of the forehead, the upper head and a part of the occiput of a human. Depending on the type of helmet, other parts of the head can also be enclosed, for example the temples and / or the chin area. Usually, a chin strap extends from the main part of such a helmet in order to secure the main part of the helmet to the head of the human wearing the helmet.

[0006] In case of traditional helmets, this main part comprises an inherently stable main body which can, for example, consist at least in parts of a foamed plastic material. Often, a soft material is provided on the inner surface of this main body.

[0007] Due to the shape of the head of the human, the main part of the helmet always comprises an inner surface which has an overall concave shape. Further, the outer surface of the main part usually has an overall convex shape. In this connection (and throughout this patent application) the terms “overall concave shape” and “overall convex shape” are to be understood in a way that isolated areas of the respective areas might not have the respective property, but the surface as a whole has this property. To give a simple example: A typical golf ball has a plurality of small indents on its surface and in an area of an indent, the surface is locally concave, but still the overall shape of the surface is a sphere and thus convex.

[0008] One drawback of helmets is that they are rather space consuming even when they are not used, for example during transportation or storage. In order to overcome this drawback, inflatable helmets comprising a first layer forming an inner layer and a second layer forming an outer layer have been proposed. According to the definitions chosen in this patent application, the first layer and the second layer form an inflatable structure or are a part of an inflatable structure which encloses a gas space. Such inflatable helmets are initially not inflated and have thus a rather flat and space-saving shape and are to be inflated prior to being used. For this reason they are also referred to as “pre-inflated helmets”. Usually, a pre-inflatable helmet can be deflated after use and for this reason, a valve, for example in form of a mouth-piece, is provided such that air can be blown into the gas space and be released from it.

[0009] Of course, it is necessary that in the inflated state, the outer surface of the first (inner) layer (the surface pointing away from the gas space) has an overall concave shape in order to conform to the shape of the part of the head covered by this first layer. As has been mentioned, it is usually also necessary that the outer surface has an overall convex shape.

[0010] Starting from this prior art, the invention sets itself the task to provide an inflatable protection device which is designed such that when the inflatable protection device is inflated to form an inflated protection device, it has a first layer whose outer surface has an overall concave shape and a second layer whose outer surface has an overall convex shape, that it is easy to manufacture. This task is solved by an inflatable protection device having the features of claim 1 . A method for manufacturing such an inflatable protection device is defined in claim 14.

[0011] The basic idea is to provide an initially flat inflatable structure comprising a first layer and a second layer that have congruent outer contours such that the inflatable structure defines a plurality of protruding areas of a first type with neighbored protruding areas of the first type being separated by non-inflatable areas, which can each be in form of an incision. The two layers are connected to each other along their outer borders defining the contour by means of a first connection such that the inflatable structure encloses a gas space. Of course, each of the two layers has an outer surface pointing away from the gas space. Because of the non-inflatable areas, neighbored protruding areas of the first type each have a border section of a first type being neighbored to each other, such that they define a pair of border sections of a first type. The border sections of the first type defining a pair of border sections of the first type are connected by means of a shaping connection of a first type that reduces the area of the non-inflatable area from a starting value to a final value, meaning that the two border sections of a pair of border sections of the first type are closer to one another after the shaping connection has been applied. Or in other words: The non-inflatable area is shortened. In case that the non-inflatable area is an incision, this incision is at least in sections closed by its shaping connection. Because of the shortening of the non-inflatable areas by means of the shaping connections, the initially flat inflatable structure cannot be brought into a flat shape without folding it along at least one folding line and when the inflatable protection device is inflated to form an inflated protection device, it “automatically” transits into a shape in which the outer surface of the first layer has an overall concave shape and the outer surface of the second layer has an overall convex shape.

[0012] The method for manufacturing the inflatable protection device has thus the following steps: (a) providing an inflatable structure comprising a first layer and a second layer, wherein

[0013] (i) the first layer and the second layer have a congruent outer contour,

[0014] (ii) each of the layers according to (i) has an outer border along which the two layers are connected by means of a first connection to form the inflatable structure which encloses a gas space,

[0015] (iii) the first layer has an outer surface pointing away from the gas space and the second layer has an outer surface pointing away from the gas space,

[0016] (iv) the inflatable structure according to (iii) has plurality of protruding areas of a first type being separated by non-inflatable areas, such that neighbored protruding areas of the first type each have a border section of a first type being neighbored to each other, such that they define a pair of border sections of a first type,

[0017] (b) connecting the border sections of the first type defining a pair of border sections of the first type according to (iv) by means of a shaping connection of a first type that at least reduces the area of the non-inflatable area.

[0018] The manufacturing process is thus very simple: Until step b), only flat elements have to be handled, which can, for example, be done with standard sewing machines or fully automated.

[0019] As has been mentioned, the inflated protection device can form a main part of a helmet adapted for covering at least a part of the forehead, the upper head and a part of the occiput of a human. In other embodiments, the inflated protection device can for example be shaped to cover the shin of a human.

[0020] If the inflatable protection device is a main part of a helmet, this helmet can especially be a full helmet comprising a central part and a chin bar extending from the central part, a bicycle-type helmet covering mainly a part of the forehead, the upper head and the occiput of a human, or a jet-type helmet. In some embodiments, the inflatable structure can comprise at least one protruding area that comprises a border section of a second type. Such a border section of the second type is characterized by the fact in a state before the shaping connections are applied, it is not neighbored to a non-inflatable area (for example an incision) and another border section. After applying the shaping connections, this border section of the second type is connected to at least one further border connection of the second type, wherein those two border sections of the second type are initially remote from one another. For example, a chinbar or a strengthened lower edge region can be generated by this. The protruding area having a border section of the second type can be a protruding area of the first type, but it can also be a protruding area of a second type not comprising a border section of the first type.

[0021] As has already been mentioned, at least one of the non-inflatable areas can be in form of an incision, especially in form of an incision that is a least in sections triangular-shaped. It can further be preferred that the shaping connection of the first type does not close this incision at its inner end, such that a ventilation hole is generated. In this case it can be preferred that the incision widens at its inner end. Of course, all non-inflatable areas can be in form of incisions and of course, a plurality of those can be shaped such that they form a ventilation hole.

[0022] In order to further improve the shape of the inflated protection device, inner connections connecting the first layer and the second layer can additionally be provided.

[0023] The invention will now be described in more detail by means of preferred embodiments in view of the figures. The figures show:

[0024] Figure 1 a cutting of a first layer,

[0025] Figure 2 a cutting of a second layer,

[0026] Figure 2a the cutting of Figure 2 after a valve has been attached to it, Figure 3 an inflatable structure formed by the parts shown in Figures 1 and 2a, a first seam and plurality of inner seams,

[0027] Figure 3a a sectional view along plane A-A in Figure 3,

[0028] Figure 4 the detail D of Figure 3,

[0029] Figure 5 what is shown in Figure 4 after a shaping seam of a first type has been applied to the border sections shown in Figure 4,

[0030] Figure 6 an inflated protection device in form of a full helmet being formed from the inflatable structure shown in Figure 3 after all shaping seams have been applied to form an inflatable protection device and after this inflatable protection device has been inflated to form the inflated protection device,

[0031] Figure 7 an alternative embodiment of an inflatable structure in a representation similar to the one of Figure 3, but with the first seam and the valve not being shown,

[0032] Figure 8 the inflated protection device formed from the inflatable structure shown in Figure 7 which is in form of a typical main part of a bicycle helmet, after all shaping seams have been applied and the resulting protection device has been inflated to form the inflated protection device, in a representation similar to the one of Figure 6,

[0033] Figure 9 an alternative to what is shown in Figure 4, and

[0034] Figure 10 what is shown in Figure 9 after a shaping seam of the first type has been applied.

[0035] Figures 1 to 6 shows the first embodiment of the invention and will now described in more detail. Figure 1 shows a first cutting forming a first layer 1 and Figure 2 shows a second cutting forming a second layer 2. In this embodiment, in which the two layers are initially separate parts, the terms “cutting” and “layer” can be used interchangeably. As one can easily see, the two layers 1 , 2 are congruent, meaning that they have an identical outer contour, such that, for example, the second layer 2 can be placed onto the first layer in such a way that they are completely aligned. The only difference between the first cutting and the second cutting (and thus the first layer 1 and the second layer 2) is that the second layer 2 comprises an inner through hole 4.

[0036] Figure 2a shows the second layer 2 of Figure 2 after a valve 5 (for example in form of a mouth piece) has been connected to it around the hole 4. The outer contour of the second layer 2 remains of course unaffected of this. The valve 5 can for example be of the type known from inflatable water wings or the like.

[0037] Figure 3 shows the parts of Figure 1 and 2a after the second layer 2 (including the valve 5) has been placed onto the first layer 1 , a first connection in form of a first seam 12 (which could also be referred to as “border connection”, “border seam” or “closing connection”) has been applied along the aligned outer borders of the first layer 1 and the second layer 2 and inner connections in form of inner seams 50 have been applied, which also connect the first layer 1 and the second layer 2. Of course, other kinds of connections, like welded or glued connections could be used, but using seams is often preferred. After those steps have been completed, an inflatable structure enclosing a gas space G is generated and the first layer 1 shows an outer surface 1 a pointing away from this gas space and the second layer 2 also shows an outer surface 2a pointing away from the gas space G as is schematically shown in Figure 3a.

[0038] In view of Figure 3, the shape of the inflatable structure (which is here essentially identical to the shape of its first layer 1 and its second layer 2) is now described in more detail, but first some remarks are made:

[0039] First it is to be noted that the inflatable structure is in this state still flat which makes it easy to apply the first seam 12 (border connection). At this point it is further to be mentioned that it is not necessary that the first layer 1 and the second layer 2 are originally separate cuttings, it would also be possible to form the inflatable structure 10 as is shown in Figure 3 by means of a one-piece-woven (OPW) process or to use a single cutting with two symmetrical sections being connected by a folding line (“butterfly design”).

[0040] Second it is to be noted that the inflatable structure 10 of the embodiment is symmetrical along the symmetry line S, such that in the following sometimes only one “half” is described, because the other half is symmetrical to the described half. Providing a symmetrical inflatable structure will often be preferred but is not strictly mandatory in each conceivable embodiment.

[0041] As one can easily see, the inflatable structure 10 comprises protruding areas, in this embodiment seven protruding areas 20, 21 , 22; 23, 23’, 22’, 21 ’. According to the definitions chosen in this application, all of those protruding areas are protruding areas of a first type. As can further be easily seen from Figure 3, neighbored protruding areas (which are protruding areas of the first type) are each separated by a non-inflatable area which is in this embodiment in form of an incision 30. In other words: The non-inflatable areas between neighbored protruding areas are thus embodied as “no material” which is usually preferred, but it would be conceivable to provide non-inflatable layer(s) between neighbored protruding areas. One can see that at least inner parts of those incisions 30 are essentially triangular-shaped.

[0042] Every protruding area 20, 21 , 22; 23, 23’, 22’, 21 ’ has two border sections of a first type as follows: protruding area 20: border sections of a first type 20a, 20b; protruding area 21 : border sections of a first type 21 a, 21 b,. protruding area 22: border sections of a first type 22a, 22b; protruding area 23: border sections of a first type 23a, 23b ... . According to the definitions chosen in this patent application, neighbored border sections define a pair of border sections of a first type: Border sections 20b and 21 a form a first pair border sections (see especially Fig. 4), border sections 21 b and 22a form a second pair border sections, border sections 22b and 23a form a third pair of border sections and so forth. Since the non-inflatable areas are embodied in as incisions, the border sections of the first type could also be denoted as “edge sections of the first type”.

[0043] In a next step, the border sections defining a pair of border section of the first type are connected to one another by means of a connection which is referred to as “shaping connection”. In this embodiment, the shaping connections are in form of shaping seams. The border sections of the first pair of border sections are connected by a first shaping seam 41 (see Figure 5), the border sections of the second pair of border sections are connected by a second shaping seam 42, the border sections of the third pair of border sections are connected by a third shaping seam 43, and so forth.

[0044] In addition, this embodiment additionally comprises two border sections of a second type 21 c, 21 c’ which are not neighbored to an incision. These two border sections of the second type 21 c, 21 c’ extend essentially parallel to one another and are located at the protruding areas 21 , 21 ’. Those two border sections of the second type 21 c, 21 c’ are also connected to one another, for example by means of a seam which is also referred to as a “shaping seam”.

[0045] After all shaping seams have been applied, the manufacture process is finished and the inflatable structure has turned to an inflatable protection device. In other words: The inflatable protection device comprises the inflatable structure plus the shaping seams. After those seams have been applied, the inflatable structure can of course no more be brought into a flat shape as is shown in Figure 3, but it still can be folded, for example along the symmetry line S which continues to exist.

[0046] When the inflatable protection device is inflated, it transforms to the inflated protection device 50 which is here a full helmet as is shown in Figure 6. In this representation, shaping seams 41 , 42, 43 are shown in the pattern dash-dot-dot- dash and inner connection seams are shown in the pattern dash-dot-dash (as in Figure 3). One can see that the outer parts 21 f, 21 f’ of the protruding areas 21 , 21 ’ which end at the border sections of the second type 21 c, 21 c’ form a chin bar of this full helmet. Figures 7 and 8 shows a second embodiment in representations similar to Figures 3 and 6 but with the first seam not being shown. The step of adding the shaping seams connecting the pairs of boarder sections of the first type is the same as just described, so that the respective description is not repeated.

[0047] Also in this embodiment, two protruding areas 24, 24’ each comprise a border section of a second type 24c, 24c’. The border area 24c of the right protruding area 24 is connected to the border sections 20c, 21 c, 22c, and 23c of the second type by means of the shaping seam 44. The border section 24c’ of the left protruding area 24’ is connected to respective further border sections in a symmetric way. Those protruding areas 24, 24’ essentially form a lower edge area of the helmet, as is shown in Figure 8.

[0048] One can see that the inventive kind of forming an inflatable protection device that turns into an inflated protection device which has an overall concave inner surface and an overall convex outer surface can be used to form various shapes of this type by simple means. Especially, all kinds of helmets (or main body of helmets) can be generated. Often, additional parts will need to be added, for example chin straps.

[0049] As is shown in Figures 9 and 10 the inventive technique can also be used for forming ventilation holes. If a ventilation hole is to be formed, the respective shaping connection 41 does not close the respective incision 30 completely to its inner end, but leaves an inner end open which then forms the ventilation hole 33. In this case it is preferred that the respective incision 30 comprises an enlarged inner end 32 which form a ventilation hole 33. An example of this is shown in Figures 9 and 10 which correspond to the Figures 4 and 5. List of reference signs

[0050] 1 first cutting forming the first layer

[0051] 1 a outer surface of first layer

[0052] 2 second cutting forming the second layer

[0053] 2’ intermediate product including second cutting and valve

[0054] 2a outer surface

[0055] 4 inner through hole in second cutting

[0056] 5 valve

[0057] 10 inflatable structure

[0058] 12 first seam (first connection) / border connection

[0059] 14 inner connection / inner seam

[0060] 20, 21 ; 21 , 22;

[0061] 23; 23’, 22’; 21 ’ protruding area of the first type 20b, 21a, 21 b, 22a, 22b, 23a,

[0062] 23b, 23a’ border section of a first type

[0063] 21 c, 21 c’, 20c, 21 c, 22c, 23c border connection of a second type 30 incision widening inner end of incision

[0064] 33 ventilation hole ventilation hole formed from widening inner end of incision

[0065] 41 , 42, 43, 44 shaping connection of a first type / shaping seam of the first type

[0066] 50 inflated protection device (helmet)

[0067] G gas space

[0068] S symmetry line

Claims

Claims1 . An inflatable protection device comprising a first layer and a second layer, wherein(i) the first layer (1 ) and the second layer (2) have a congruent outer contour,(ii) each of the layers according to (i) has an outer border along which the two layers are connected by means of a first connection to form the inflatable structure (10) which encloses a gas space (G),(iii) the first layer has an outer surface (1 a) pointing away from the gas space (G) and the second layer (2) has an outer surface (2a) pointing away from the gas space (G),(iv) the inflatable structure according to (ii) has plurality of protruding areas of a first type (20, 21 , 22, 23, 23’, 22’, 21 ’) being separated by non-inflatable areas (30), such that neighbored protruding areas of the first type (20, 21 , 22, 23, 23’, 22’, 21 ’) each have a border section of a first type (20, 21a; 21 b, 22a; 22b, 23a; ) being neighbored to each other, such that they define a pair of border sections of a first type (20b, 21 a; 21 b, 22a; ...),(v) the border sections of the first type defining a pair of border sections of the first type according to (iv) are connected by means of a shaping connection of a first type (41 , 42, 43) that reduces the area of its allocated non-inflatable area, such that when the inflatable protection device is inflated to form an inflated protection device (50), the outer surface (1 a) of the first layer (1 ) according to (iii) has an overall concave shape and the outer surface (2a) of the second layer (2) according to (iii) has an overall convex shape.

2. The inflatable protection device of claim 1 , wherein the inflated protection device (50) forms a main part of a helmet adapted for covering at least a part of the forehead, the upper head and a part of the occiput of a human.

3. The inflatable protection device of claim 2, wherein said helmet is a full helmet comprising a central part and a chin bar extending from the central part.

4. The inflatable protection device of claim 2, wherein the helmet is a bicycle-type helmet.

5. The inflatable protection device of claim 2, wherein the helmet is a jettype helmet.

6. The inflatable protection device of any one of the preceding claims, wherein the inflatable structure according to (ii) comprises at least one protruding area (21 , 21’, 24, 24’) comprising a border section of a second type (21 c, 21 c’, 24c, 24c’) being connected to at least one further border section of the second type (21 c, 21 c’, 20c, 21 c, 22c, 23c).

7. The inflatable protection device of claim 6 as long as referring to claim 3, wherein the at least one protruding area comprising the border section of the second type (21 c, 21 c’) forms the chin bar.

8. The inflatable protection device of claim 6 as long as referring to claim 4, wherein the at least one protruding area comprising the border section of the second type (24c) forms a least a section of a lower edge area of the bicycle-type helmet.

9. The inflatable protection device of at least one of the preceding claims, wherein at least one of the non-inflatable areas is an incision (30) that is at least in sections closed by its shaping connection (41 , 42, 43), wherein it is preferred that the incision (30) is at least in sections triangularshaped before being closed by the shaping connection (41 , 42, 43) and wherein it is further preferred that all non-inflatable areas are incisions (30).

10. The inflatable protection device of claim 9, wherein at least one shaping connection of the first type (41 ) does not close the incision (30) at its inner end, such that a ventilation hole (33) is generated.1 1 . The inflatable protection device of claim 10, wherein the incision (30) has a widening inner end (32) forming the ventilation hole (32) after the shaping connection of the first type (41 ) has been applied.

12. The inflatable protection device of any one of the preceding claims, wherein the first layer (1 ) and the second layer (2) are additionally connected to one another by means of a plurality of inner connections (14).

13. An inflated protection device (50) being generated by inflating an inflatable protection device of any one of claims 1 to 12.

14. Method for forming an inflatable protection device of any one of claims 1 to 13 comprising the following steps:(a) providing an inflatable structure (10) comprising a fist layer (1 ) and a second layer (2), wherein(i) the first layer (1 ) and the second layer (2) have a congruent outer contour,(ii) each of the layers according to (i) has an outer border along which the two layers are connected by means of a first connection (12) to form the inflatable structure (10) which encloses a gas space (G),(iii) the first layer has an outer surface (1 a) pointing away from the gas space (G) and the second layer (2) has an outer surface (2a) pointing away from the gas space (G),(iv) the inflatable structure has plurality of protruding areas of a first type (20, 21 , 22, 23, 23’, 22’, 21 ’) being separated by non-inflatable areas (30), such that neighbored protruding areas of the first type (20, 21 , 22, 23, 23’, 22’, 21 ’) each have a border section of a first type (20, 21 a; 21 b, 22a; 22b, 23a; > ) being neighbored to each other, such that theydefine a pair of border sections of a first type (20b, 21 a;21 b, 22a; ...),(b) connecting the border sections of the first type defining a pair of border sections of the first type according to (iv) by means of a shaping connection (41 , 42, 43) of a first type that at least reduces the area of the non-inflatable area.

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