Helmet and method for assembling a helmet

Abstract

A helmet (1) for protecting a wearer's head comprising an outer energy absorbing layer (2) configured to absorb energy at impact on the helmet; a substantially rigid outer shell configured to at least partly engage and cover an outer surface of the outer energy absorbing layer, the helmet further comprising an inner energy absorbing layer (3) configured to absorb energy at impact on the helmet; and a connector element (4).

Description

[0001] HELMET AND METHOD FOR ASSEMBLING A HELMET

[0002] Field of the Invention

[0003]

[0001] The present invention generally relates to a helmet, in particular for sports, more in particular for cycling, and a method for assembling said helmet.

[0004] Background of the Invention

[0005]

[0002] Helmets for protecting a wearer’s head are well known and generally used in a variety of sports such as cycling, horse riding, climbing, skiing and other sports. Such helmets generally comprise an energy absorbing layer configured to at least partly absorb a shock of an impact. Said energy absorbing layer can be relatively thick and may for example be made of expanded polystyrene (EPS). The helmets further comprise an outer shell at least partly covering said energy absorbing layer. Said outer shell may be relatively thin and lightweight and is generally made of a substantially rigid material, such as for example carbon fibre, polycarbonate or ABS. The outer shell can be glued to the energy absorbing layer, or the energy absorbing layer and the outer shell can be chemically bonded, for example by in-moulding, which is a generally known but relatively difficult process for manufacturing helmets. Alternatively, the outer shell and the energy absorbing layer may be connected in any other known manner, for example by one or more connector elements.

[0006]

[0003] Since an impact on a helmet is rarely directed substantially transversely to said helmet, an impact generally includes a linear and a tangential component and rotational impact absorption has become an issue in the helmet industry. Different solutions have been proposed, such as rotational impact absorption through sliding layers or through breaking protrusions. Depending on the type of impact component to be absorbed, and on the impact force, various materials may be used, and / or various densities of material to manufacture the energy absorbing layer. However, the manufacturing of said energy absorbing layer has been become relatively complicated while there is still room for improvement on shock absorption.

[0004] It is therefore an aim of the present invention to solve or at least alleviate one or more of the above-mentioned problems. In particular, the invention aims at providing a helmet with improved shock absorption which is relatively easy to assemble and a method for assembling said helmet allowing relatively swift assembly.

[0007] Summary of the Invention

[0008]

[0005] To this aim, according to a first aspect of the invention, there is provided a helmet having the features of claim 1 . In particular, the helmet for protecting a wearer’s head comprises an outer energy absorbing layer configured to absorb energy at impact on the helmet, as well as a substantially rigid outer shell configured to at least partly engage and cover an outer surface of the outer energy absorbing layer. The substantially rigid outer shell may be relatively thin and lightweight and may for example be a shell made in carbon fibre, polycarbonate or ABS. The substantially rigid outer shell can be glued on the outer surface of the outer energy absorbing layer or may be chemically bonded to the outer energy absorbing layer. Alternatively, the substantially rigid outer shell may be fixedly connected to the outer energy absorbing layer in any other known way, for example through a mechanical connector configured to fixedly connect said substantially rigid shell to said outer energy absorbing layer. In an inventive way, the helmet further comprises an inner energy absorbing layer configured to absorb energy at impact on the helmet and at least one connector element configured to provide a rigid connection between said outer energy absorbing layer and said inner energy absorbing layer. In other words, the outer energy absorbing layer and the inner energy absorbing layer are two separate or discrete pieces or elements which are connected to each other via said at least one connector element in a substantially rigid way, implying that no relative movement, such as rotation or sliding, is possible between the outer energy absorbing layer and the inner energy absorbing layer. The rigid or locked connection can thus be described as a movement- free connection. The at least one connector element is preferably also configured to provide a fixed connection, in contrast to releasable connection elements. The rigid connection between said outer energy absorbing layer and said inner energy absorbing layer does not imply that the at least one connector element should be a rigid element.

[0006] The inner energy absorbing layer can advantageously include an outwardly protruding flange configured to engage a lower rim or edge of the outer energy absorbing layer. Said outwardly protruding flange can provide a firm engagement of the inner energy absorbing layer on the outer energy absorbing layer preventing any relative movement between said two energy absorbing layers. The outwardly protruding flange can be shaped and dimensioned such that an outer surface of the outer energy absorbing layer may be substantially flush with an outer surface of the inner energy absorbing layer at an engagement line between the two energy absorbing layers when connected to each other.

[0009]

[0007] The outwardly protruding flange may extend along substantially an entire contour of the inner energy absorbing layer. In other words, the outwardly protruding flange may extend circumferentially around the inner energy absorbing layer, or, when the helmet is worn by a user, may be a circum-cranial flange. Such a circumferential or circum-cranial flange can provide a solid base for supporting the outer energy absorbing layer in a substantially rigid or movement-free way. Alternatively, the outwardly protruding flange could extend along a contour of the inner energy absorbing layer only partially.

[0010]

[0008] The at least one connector element can for example be configured to connect the outwardly protruding flange of the inner energy absorbing layer with the lower rim of the outer energy absorbing layer. Such a positioning of the at least one connector element can provide a rigid and preferably non-releasable connection while at the same time, manufacturing and mounting of the helmet can be simplified, which can save production time and thus costs. Alternatively, the at least one connector elements can be positioned elsewhere, such as along an outer surface or an inner surface of the outer and inner energy absorbing layers.

[0011]

[0009] The at least one connector element may preferably be a mechanical connector element, in particular a snap connector assembly. As is known to the person skilled in the art, a snap connector assembly includes an insertable element attached to one of the inner energy absorbing layer and the outer energy absorbing layer, and a corresponding receiving element, which is attached to the other of the inner energy absorbing layer and the outer energy absorbing layer. The receiving element is configured to receive the insertable element such that the insertable element is fixedly gripped within the receiving element. A snap connector assembly is relatively easy to assemble while providing a rigid connection between the inner energy absorbing layer and the outer energy absorbing layer. Other mechanical connector elements can for example include screws or other connection means. Alternatively, the inner energy absorbing layer and the outer energy absorbing layer can be connected via nonmechanical connector elements, such as adhesive, double-sided tape or other known connection means.

[0012]

[0010] It may be preferred that the outer energy absorbing layer is at least partly in direct engagement with said inner energy absorbing layer when connected. Since the inner energy absorbing layer and the outer energy absorbing layer are rigidly connected via the at least one connector elements, there is no need for any intermediate layer configured to facilitate moving or sliding of layers. To the contrary, the direct engagement of at least part of an outer surface of the inner energy absorbing layer and an inner surface of the outer energy absorbing layer can contribute to the rigid connection between the inner energy absorbing layer and the outer energy absorbing layer.

[0013]

[0011] The outer energy absorbing layer and the inner energy absorbing layer can preferably be discrete and separately manufactured elements. Separate manufacturing of the inner energy absorbing layer and the outer energy absorbing layer can simplify and speed up the manufacturing of the helmet. At the same time, separate manufacturing of the discrete elements can allow a variety of combinations of materials and densities for the inner energy absorbing layer and the outer energy absorbing layer without complicating the manufacturing process.

[0014]

[0012] The inner energy absorbing layer and the outer energy absorbing layer can advantageously each be substantially a dome-shaped element. Dome-shaped elements can be connected in a rigid way relatively easily, for example with at least three spaced apart connection elements preventing any relative movement between the inner energy absorbing layer and the outer energy absorbing layer. Alternatively, one of the inner energy absorbing layer and the outer energy absorbing layer may also have a different shape and extend over only part of the head of a user.

[0013] The inner energy absorbing layer and the outer energy absorbing layer may advantageously be made of a same material. As an example, both the inner energy absorbing layer and the outer energy absorbing layer may be made of expanded polystyrene (EPS) or expanded polypropylene (EPP). Using a single material for both the inner energy absorbing layer and the outer energy absorbing layer can simplify manufacturing. Alternatively, each of the inner energy absorbing layer and the outer energy absorbing layer could also be made of a different material depending on a type of force the layer is configured to absorb.

[0015]

[0014] A density of the inner energy absorbing layer may be different from, in particular lower than, a density of the outer energy absorbing layer. The inner absorbing layer may for example be configured to absorb a rotational component of an impact, for which a relatively low density of material may be suited, while the outer energy absorbing layer may be configured to absorb a linear component of said impact, for example through compression, for which a relatively high density may be suited. The opposite may also be feasible: a lower density for the outer energy absorbing layer and a higher density for the inner energy absorbing layer. In some cases, it may also be considered to use a relatively low density to absorb a linear component and a relatively high density to absorb a rotational component of an impact.

[0016]

[0015] The inner energy absorbing layer and / or the outer energy absorbing layer can advantageously include at least one slit to obtain a weakened portion or spot in the energy absorbing layer, the portion being configured to break, fracture or rupture when an impact exceeds a predefined threshold. The at least one slit is to be understood as an elongated through-hole in the material of the inner energy absorbing layer and / or the outer energy absorbing layer. The presence of the slit can create a consciously weakened spot or portion in the energy absorbing layer. Such a weakened spot can then cause a breach or a fracture in the energy absorbing layer, which can contribute to absorbing a rotational component of an impact exceeding a predefined threshold. At the same time, a visual fracture in the inner energy absorbing layer can indicate to the user that the helmet needs replacement due to an impact.

[0017]

[0016] Said at least one slit may for example be a U-shaped slit. A U-shaped slit can create a weakened spot or portion shaped as a peninsula almost entirely surrounded by the slit, the peninsula being configured to break off when an impact exceeds a predetermined threshold. The slit can also have other shapes, such as for example an S-shaped or Z-shaped slit, or any other regular or irregular shaped slit, which can create the effect of weakened spots configured to break off. The weakened spots in the inner or outer energy absorbing layer may preferably be bound or defined by at least one slit for at least 40%, more preferably 50% or more of a contour of said weakened portion to improve the breaking off capacity.

[0018]

[0017] The helmet may further include a third energy absorbing layer configured to be positioned between the inner energy absorbing layer and the outer energy absorbing layer. Such a third energy absorbing layer may be held in place by being sandwiched or trapped between the inner energy absorbing layer and the outer energy absorbing layer which are rigidly connected to each other. Said third energy absorbing layer may be made of the same material as one or both of the inner energy absorbing layer and the outer energy absorbing layer. So, this third energy absorbing layer is not a movement facilitating layer. Even if there may not be direct engagement of the inner energy absorbing layer and the outer energy absorbing layer, the third energy absorbing layer may be at least partly in direct engagement with the inner energy absorbing layer and the outer energy absorbing layer, thus contributing to the rigid connection of the energy absorbing layers. The third energy absorbing layer may, but need not, be made of the same material as one or both of the outer and inner energy absorbing layer. A density of the material of said third energy absorbing layer may, but need not be, the same as one or both of the densities of the outer and inner energy absorbing layer.

[0019]

[0018] The inner energy absorbing layer can include a plurality of protrusions extending towards a wearer’s head, the protrusions being configured to break when an impact exceeds a predefined threshold. The breaking of the protrusions can absorb at least part of the energy caused by a tangential component of an impact. The breaking does not only improve safety of the helmet through improved rotational impact protection, but also serves as a warning to the user that the helm has undergone a serious impact and should be replaced. When said protrusions are directly towards a wearer’s head, they also allow circulation of air in between said protrusions, which can improve ventilation of the head. Alternatively, the outer energy absorbing layer can include protrusions extending away from a user’s head, or the outer energy absorbing layer can include protrusions extending towards a wearer’s head and protrusions extending away from a user’s head, the protrusions being configured to break when an impact exceeds a predefined threshold.

[0020]

[0019] The helmet may further include ventilation holes extending through the inner energy absorbing layer, the outer energy absorbing layer and the substantially rigid outer shell. Ventilation holes extending through all the layers of the helmet can improve air circulation around the head of the user, which can improve comfort.

[0021]

[0020] According to a second aspect of the invention, there is provided a method for manufacturing a helmet having the features of claim 16. The method can provide one or more of the above-mentioned advantages.

[0022] Brief Description of the Drawings

[0023]

[0021] Figs. 1 a and 1 b show a side view and an exploded side view respectively of a preferred embodiment of a helmet according to a first aspect of the invention;

[0024]

[0022] Fig. 2 shows an exploded perspective view of the helmet of Figure 1 a;

[0025]

[0023] Figs. 3a and 3b show a top view of the outer energy absorbing layer and the inner energy absorbing layer respectively of the helmet of Figure 1a;

[0026]

[0024] Fig. 4 shows a schematic cross-sectional side view the helmet of Figure 1 a;

[0027]

[0025] Fig. 5 shows a schematic exploded side view of a second embodiment of a helmet according to a first aspect of the invention;

[0028]

[0026] Fig. 6 shows a schematic exploded side view of a third embodiment of a helmet according to a first aspect of the invention;

[0029]

[0027] Fig. 7 shows a schematic cross-sectional side view of a fourth embodiment of a helmet according to a first aspect of the invention;

[0028] Fig. 8a and 8b show a top view and a cross-sectional side view along section A - A of a fifth embodiment of a helmet according to a first aspect of the invention;

[0030]

[0029] Fig. 9 shows a bottom view of the helmet of Figure 8a.

[0031] Detailed Description of Embodiment(s)

[0032]

[0030] Figures 1 a and 1 b show a side view and an exploded side view respectively of a preferred embodiment of a helmet 1 according to a first aspect of the invention. The helmet 1 protects a wearer’s head, in particular during sports activities such as for example during cycling, mountain-biking, bicycle racing or other sports. The helmet 1 comprises an outer energy absorbing layer 2 configured to absorb energy at impact on the helmet, and a substantially rigid outer shell configured to at least partly engage and cover an outer surface of the outer energy absorbing layer, which is not shown in the Figures. Said outer shell is known to be relatively thin and light-weight and is generally made of a substantially rigid material, such as for example carbon fibre, polycarbonate or ABS. The outer shell can be glued to the outer energy absorbing layer 2, or the outer energy absorbing layer 2 and the outer shell can be chemically bonded, for example by in-moulding, which is a generally known process for manufacturing helmets. Alternatively, the outer shell and the outer energy absorbing layer 2 may be connected in any other known manner, for example by one or more connector elements. The outer energy absorbing layer 2 may for example be made of expanded polystyrene (EPS) or of any other material suitable for shock absorption. In an inventive way, the helmet further comprises an inner energy absorbing layer 3 configured to absorb energy at impact on the helmet and at least one connector element 4 configured to provide a rigid connection between said outer energy absorbing layer 2 and said inner energy absorbing layer 3. The outer energy absorbing layer 2 and the inner energy absorbing layer 3 are discrete and preferably separately manufactured elements, which are connected to each other in a separate mounting step of the helmet 1 . The inner energy absorbing layer 3 and the outer energy absorbing layer 2 may be made of a same material, such as expanded polystyrene (EPS) or expanded polypropylene (EPP), but may also each be made of a different material, for example depending on a type of shock the layer is configured to absorb. Additionally, and / or alternatively, a density of the inner energy absorbing layer 3 may be the same or different from, in particular higher than, a density of the outer energy absorbing layer 2, also depending on a type of shock the layer is configured to absorb. As an example, a lower density of material may be used to absorb a rotational component of an impact while a higher density may be used to absorb a linear component of an impact. The choice for a material and / or a density may also depend on the way the layer is configured to absorb an impact: absorption by compression may require a specific material and / or a lower density than for example shock absorption by rupturing of material. By providing an outer energy absorbing layer 2 and an inner energy absorbing layer 3, manufacturing of different types of helmets tailored to specific needs and requirements can be simplified.

[0033]

[0031] Figure 2 shows an exploded perspective view of the helmet of Figure 1 a. As can be seen in the figures, the inner energy absorbing layer 3 and the outer energy absorbing layer 2 can preferably each be substantially dome-shaped elements. The inner energy absorbing layer 3 can preferably include an outwardly protruding flange 5 configured to engage a lower rim 6 of the outer energy absorbing layer 2. The outwardly protruding flange 5 may, but need not, extend along substantially an entire contour of the inner energy absorbing layer 3. Said flange 5 can prevent relative movement of the outer energy absorbing layer 2 over the inner energy absorbing layer 3 and provide a rigid connection between said layers. The at least one connector element 4 may for example be a mechanical connector element, in particular a snap connector assembly, including for example an insertable element and a corresponding receiving element configured to receive said insertable element in a fixed way. The at least one connector element 4 may be configured to connect the outwardly protruding flange 5 of the inner energy absorbing layer 3 with the lower rim 6 of the outer energy absorbing layer 2. Thereto, the insertable element of a snap assembly may for example extend from a lower rim 6 of the outer energy absorbing layer 2, while the outwardly extending flange 5 of the inner energy absorbing layer 3 may include corresponding receiving elements 7. In this way, the outer energy absorbing layer 2 can be mounted relatively easily on the inner energy absorbing layer 3 by just clicking the insertable snap connector elements 4 into the receiving elements 7. Said mechanical connector elements 4 may be spaced apart along a contour of the outer and / or inner energy absorbing layer. The helmet can for example include at least three or four connector elements configured to connect said outer energy absorbing layer 2 to said inner energy absorbing layer 3. It will be clear to the person skilled in the art that the elements of the snap connector assembly may be inversed between the inner and outer energy absorbing layer, and that other connecting means, in particular mechanical connector elements, may be used to an advantage as well, without compromising the substance of the invention of providing two energy absorbing layers which are rigidly connected to each other.

[0034]

[0032] Figures 3a and 3b show a top view of the outer energy absorbing layer 2 and the inner energy absorbing layer 3 respectively of the helmet of Figure 1 a. As can be seen in Figure 3b, the inner energy absorbing layer 3 can include at least one slit 8 to obtain a weakened portion 9 in the energy absorbing layer configured to break, fracture or rupture when an impact exceeds a predefined threshold. The slit 8 is an elongated through-hole through the material of the inner energy absorbing layer 3. Said at least one slit 8 may have different shapes, as shown, and may be substantially straight, curved, Z-shaped, S-shaped, L-shaped, U-shaped or any other regular or irregular shape. The resulting weakened portion 9 may be positioned near or around said slit, or in between two of such slits 8. In case of a U-shaped or V-shaped slit 8, the slit 8 may create a kind of weakened peninsula between the legs of the U-shaped slit 8. Even if the at least one slit 8 may also be included in the outer energy absorbing layer 2, which is not the case in Figure 3a, it is preferred that said at least one slit 8 does not extend through both the inner energy absorbing layer 3 and the outer energy absorbing layer 2. By having said at least one slit 8 and the weakened portion 9 in only one energy absorbing layer, the helmet 1 can provide a minimum of shock absorbing layer thickness by one of the energy absorbing layers while the slits in the other energy absorbing layer can improve impact protection against a rotational component of said impact through the rupturing of the weakened portions when an impact is above a predefined threshold. In contrast to the at least one slit 8, the helmet 1 may further include ventilation holes 10 extending through the inner energy absorbing layer 3, the outer energy absorbing layer 2 and the substantially rigid outer shell, which is not shown here. Said ventilation holes 10 can allow air circulation within the helmet for cooling a wearer’s head.

[0035]

[0033] Figure 4 shows a schematic cross-sectional side view the helmet of Figure 1 a when the outer energy absorbing layer 2 is rigidly connected to the inner energy absorbing layer 3 through the connector elements 4 snapped into the receiving elements 7 of the snap connector assembly. It is clear that other types of connector elements could be used as well, or that the connector elements could be mounted and / or positioned differently. Said cross-sectional view also clearly shows the ventilation holes 10 extending through both said outer energy absorbing layer 2 and said inner energy absorbing layer 3. It is further preferred that the outer energy absorbing layer 2 is at least partly in direct engagement with said inner energy absorbing layer 3 when connected. Since there is a fixed and rigid connection between the outer energy absorbing layer and the inner energy absorbing layer, there is no need for any intermediate layer, such as an elastomeric layer, for example to facilitate any movement between the layers. To the contrary, direct engagement of at least part of the outer and inner energy absorbing layers can contribute to the rigid connection between the layers.

[0036]

[0034] Figure 5 shows a schematic exploded side view of a second embodiment of a helmet according to a first aspect of the invention. The helmet T comprises an outer energy absorbing layer 2 including the same features as described with respect to preceding figures illustrating a preferred embodiment. The helmet T further comprises an inner energy absorbing layer 3’ which includes at least two separate portions, an upper portion 3a and a lower portion 3b. Each of these at least two portions 3a, 3b need not be dome-shaped elements, but when the at least two portions are connected, they can form an inner energy absorbing layer 3’ which is dome-shaped. In this way, a density and / or a material of at least the upper portion 3a and the lower portion 3b can be customized separately. In particular, portions of the inner energy absorbing layer 3’ can be weakened or strengthened locally without complicating the manufacturing process. The outer energy absorbing layer 2 is connected to the inner energy absorbing layer 3’ via connector elements 4, which may be similar to the preceding embodiment, in particular a snap connector assembly. In particular, the inserting elements 4 attached to a lower rim of the outer energy absorbing layer 2 can be inserted or snapped into receiving elements positioned along the outwardly protruding flange 5 of the lower portion 3b of the inner energy absorbing layer 3’. The upper portion 3a of the inner energy absorbing layer may, but need not, be fixedly connected to the lower portion 3b of the inner energy absorbing layer 3’. Said upper portion 3a may just be mounted on the lower portion 3b by form-fit and be maintained in place by being trapped between the outer energy absorbing layer 2 rigidly connected to the lower portion 3b of the inner energy absorbing layer 3’.

[0037]

[0035] Figure 6 shows a schematic exploded side view of a third embodiment of a helmet according to a first aspect of the invention. The idea is similar to the embodiment shown in Figure 5: the helmet 1” comprises an outer energy absorbing layer 2 including the same features as described with respect to preceding figures illustrating a preferred embodiment. The helmet 1” further comprises an inner energy absorbing layer 3” which includes two separate portions, an upper portion 3a and a lower portion 3b. The difference lies in the way the inner energy absorbing layer 3” is divided into the two portions 3a and 3b. In particular, the upper portion 3a, which is configured to protect a crown of a user’s head, may benefit from a different material and / or a different density of material to improve protection, as explained with respect to Figure 5. As previously explained, the upper portion 3a may be fixedly connected to the lower portion 3b via dedicated connecting means, or the upper portion 3a may form-fit on the lower portion 3b and be sandwiched between the outer energy absorbing layer 2 rigidly connected to the lower portion 3b of the inner energy absorbing layer 3”.

[0038]

[0036] Figure 7 shows a schematic cross-sectional side view of a fourth embodiment of a helmet 100 according to a first aspect of the invention. The helmet 100 comprises an outer energy absorbing layer 2 and an inner energy absorbing layer 3 rigidly connected to each other via the connector elements 4 embodied as insertion elements received in receiving elements 7 along an outwardly protruding flange 5 of the inner energy absorbing layer 3, said energy absorbing layers 2, 3 and connector elements 4 including the same features as described with respect to preceding figures illustrating a preferred embodiment. The helmet 100 differs from the preceding embodiments in that the helmet 100 further includes a third energy absorbing layer 11 configured to be positioned between the inner energy absorbing layer 3 and the outer energy absorbing layer 2. Said third energy absorbing layer 11 is also configured to absorb an impact, for example a linear component of an impact, for example by compression, and may be made of the same material, or a different material, and / or a same density or a different density, as one or both of the inner energy absorbing layer 3 and the outer energy absorbing layer 2. The third energy absorbing layer 11 may, but need not, be rigidly connected to one or both of the inner energy absorbing layer 3 and the outer energy absorbing layer 2 via dedicated connection means. The third energy absorption layer 11 can for example just be sandwiched between the inner energy absorbing layer 3 and the outer energy absorbing layer 2 which are rigidly connected to each other. When the helmet 100 further includes ventilation holes 10, said ventilation holes 10 preferably also extend through said third energy absorbing layer 11 .

[0039]

[0037] Figures 8a and 8b show a top view and a cross-sectional side view along section A - A of a fifth embodiment of a helmet 200 according to a first aspect of the invention. In analogy with the preferred embodiment schematically shown in Figures 1 - 4, the helmet 200 comprises an outer energy absorbing layer 2 and an inner energy absorbing layer 3 rigidly connected to each other via connector elements 4. Figures 8a and 8b also show a substantially rigid outer shell 12 configured to at least partly engage and cover an outer surface of the outer energy absorbing layer 2. The helmet 200 further includes ventilation holes 10 extending through the inner energy absorbing layer 3, the outer energy absorbing layer 2 and the substantially rigid outer shell 12. One or more of said ventilation holes 10, for example at a back of the helmet, may include an insert 17 configured to receive a goggle strap. Other ventilation holes 10 may also be configured to receive inserts for other purposes. The helmet 200 further includes a retention system 13 attached to an inner side of the inner energy absorbing layer 3. The retention system 13 may include a head basket or a headband 14 and an adjustment system 15 configured to adjust a headband around a wearer’s head. Said adjustment system 15 may include an operating element, such as rotary knob or an endless band, or may be a self-adjusting system.

[0040]

[0038] Figure 9 shows a bottom view of the helmet of Figure 8a. The inner energy absorbing layer 3 includes a plurality of protrusions 16 extending towards a wearer’s head, the protrusions 16 being configured to break, fracture or rupture when an impact exceeds a predefined threshold. Said protrusions have a truncated pyramidal shape and have varying sizes depending on a position within the helmet. At the same time, the inner energy absorbing layer 3 can include slits 8 creating a weakened portion 9 in the energy absorbing layer 3. Said weakened portion(s) 9 are also configured to break, fracture or rupture when an impact exceeds a predefined threshold. Said slits 8 do preferably not extend through the outer energy absorbing layer 2 while the ventilation holes 10 do extend through all of the layers of the helmet 200.

[0041]

[0039] Although the present invention has been illustrated by reference to specific embodiments, it will be apparent to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied with various changes and modifications without departing from the scope thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. In other words, it is contemplated to cover any and all modifications, variations or equivalents that fall within the scope of the basic underlying principles and whose essential attributes are claimed in this patent application. It will furthermore be understood by the reader of this patent application that the words "comprising" or "comprise" do not exclude other elements or steps, that the words "a" or "an" do not exclude a plurality, and that a single element, such as a computer system, a processor, or another integrated unit may fulfil the functions of several means recited in the claims. Any reference signs in the claims shall not be construed as limiting the respective claims concerned. The terms "first", "second", third", "a", "b", "c", and the like, when used in the description or in the claims are introduced to distinguish between similar elements or steps and are not necessarily describing a sequential or chronological order. Similarly, the terms "top", "bottom", "over", "under", and the like are introduced for descriptive purposes and not necessarily to denote relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances and embodiments of the invention are capable of operating according to the present invention in other sequences, or in orientations different from the one(s) described or illustrated above.

Claims

CLAIMS1 . A helmet for protecting a wearer’s head comprising- an outer energy absorbing layer configured to absorb energy at impact on the helmet;- a substantially rigid outer shell configured to at least partly engage and cover an outer surface of the outer energy absorbing layer, wherein said helmet further comprises- an inner energy absorbing layer configured to absorb energy at impact on the helmet;- at least one connector element configured to provide a rigid connection between said outer energy absorbing layer and said inner energy absorbing layer.

2. The helmet according to claim 1 , wherein the inner energy absorbing layer includes an outwardly protruding flange configured to engage a lower rim of the outer energy absorbing layer.

3. The helmet according to claim 2, wherein the outwardly protruding flange extends along substantially an entire contour of the inner energy absorbing layer.

4. The helmet according to any of the preceding claims 2 - 3, wherein the at least one connector element is configured to connect the outwardly protruding flange of the inner energy absorbing layer with the lower rim of the outer energy absorbing layer.

5. The helmet according to any of the preceding claims, wherein the at least one connector element is a mechanical connector element, in particular a snap connector assembly.

6. The helmet according to any of the preceding claims, wherein said outer energy absorbing layer is at least partly in direct engagement with said inner energy absorbing layer when connected.

7. The helmet according to any of the preceding claims, wherein the outer energy absorbing layer and the inner energy absorbing layer are discrete and separately manufactured elements.

8. The helmet according to any of the preceding claims, wherein the inner energy absorbing layer and the outer energy absorbing layer are each substantially dome-shaped elements.

9. The helmet according to any of the preceding claims, wherein the inner energy absorbing layer and the outer energy absorbing layer are made of a same material.

10. The helmet according to any of the preceding claims, wherein a density of the inner energy absorbing layer is different from, in particular lower than, a density of the outer energy absorbing layer.11 . The helmet according to any of the preceding claims, wherein the inner energy absorbing layer and / or the outer energy absorbing layer includes at least one slit to obtain a weakened portion in the energy absorbing layer configured to break when an impact exceeds a predefined threshold.

12. The helmet according to claim 11 , wherein said at least one slit is a U-shaped slit.

13. The helmet according to any of the preceding claims, further including a third energy absorbing layer configured to be positioned between the inner energy absorbing layer and the outer energy absorbing layer.

14. The helmet according to any of the preceding claims, wherein the inner energy absorbing layer includes a plurality of protrusions extending towards a wearer’s head, the protrusions being configured to break when an impact exceeds a predefined threshold.

15. The helmet according to any of the preceding claims, further including ventilation holes extending through the inner energy absorbing layer, the outer energy absorbing layer and the substantially rigid outer shell.

16. Method for manufacturing a helmet for protecting a wearer’s head, the method comprising the steps of - providing an inner energy absorbing layer;- providing an outer energy absorbing layer;- providing a substantially rigid outer shell;- providing at least one connector element;- laying the outer energy absorbing layer over the inner energy absorbing layer such that said outer energy absorbing layer is at least partly in direct engagement with said inner energy absorbing layer;- having said at least one connector element provide a rigid connection between said outer energy absorbing layer and said inner energy absorbing layer connecting.

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