The present invention relates to the field of bicycle helmets. Specifically, the present invention relates to bicycle helmets having a sun visor.
Bicycle helmets are used for protecting a rider's head during, for example, a crash or a fall. Such helmets are typically formed by well known processes involving the use of a hollow mould into which an expandable material, such as a foam and/or a foam precursor is added. The mould is typically heated up prior to or during the process, and often a vacuum is applied to help expand the foam and/or foam precursor.
In-moulding, also known as injection-moulding and co-injection moulding, is well-known in the art of helmet making for combining a hard outer layer with an inner polystyrene shape. Processes are also known for adding a lacquered outer layer to a Styrofoam, polystyrene foam, or other foam helmet. Other processes are known for injecting a pre-mixture of, for example expandable poly styrene (EPS) beads and spongy particles into a mould together so as to allegedly produce a helmet with a balance between impact protection and impact absorption. In some cases expandable poly propylene (EPP) beads are used as well. Some processes apply different materials into the mould at the same time, while other processes first form the pieces separately and then affix them together afterwards.
Face shields are also well-known in full-face helmets, such as motorcycle/racing helmets and dirt bike helmets. In a racing helmet the face shield is typically formed of Plexiglas or other clear plastic and tends to cover the face, either partially or completely. Such a clear face shield is often required for safety and to meet various regulatory requirements. Face shields are often able to pivot up relative to the bicycle helmet so as to, for example, allow the user to clean condensation from the inside of the bicycle helmet without taking it off. However, such face shields are intended to be permanently affixed to the bicycle helmet as removing them may potentially cause safety issues during subsequent use.
In cases such as horse riding and BMX-biking, full-face helmets are sometimes used and these may have sun visors affixed thereupon. Such sun visors are opaque and shield the face from the sun much like the bill of a baseball cap. Such sun visors are typically permanently fixed to the bicycle helmet and are unmovable—i.e., they are not intended to be removed by the bicycle helmet user.
Recently, bicycle racing helmets have been developed which combine the face-shield in a racing helmet with an abbreviated face shield, for cases where the rider is riding into the sun. Such helmets are typically not full-face helmets, but instead only cover the crown of the head, and do not cover the ears, back of the neck, chin, etc. Such helmets are available from, for example, CRATONI® as the EVOLUTION. However, the shields of such helmets are like racing helmets, permanently affixed to the bicycle helmet and not intended to be removed by the user.
GIRO recently released the GIRO BELL XAR helmet having a “Point of View” (a.k.a., “POV”) sun visor that pivots up to 15° and is intended for mountain biking, trail biking, endurance riders, etc. The POV sun visor (see, for example: http://www.youtube.com/watch?v=65AtDHnJI7k) allegedly has an internal clutch mechanism which fixes it in place. However, such a pivoting mechanism for an adjustable visor has certain drawbacks. For example, and as seen in the above video, when it is raised up, it may in some cases slowly fall down and otherwise fail to remain in a fixed position. This may be especially frustrating when the user travels over bumpy or uneven terrain which may make the POV visor undesirably move from the position that the user adjusted it to.
Accordingly, there remains a need for a bicycle helmet having a pivoting visor which is, for example, easily constructed in an efficient manner, has a removable or replaceable sun visor, and/or, stays in a relatively fixed position unless specifically adjusted by the user.
The present invention relates to an improved bicycle helmet includes an inner layer having a concave shape, an outer layer having a convex shape, and a sun visor. The outer layer covers the inner layer and includes an outer layer attachment member and an outer layer lock member. The sun visor includes a shade member and a sun visor attachment member connected to and distal to the shade member. The sun visor attachment member is adapted to rotatably engage with the outer layer attachment member to form a fulcrum. The sun visor lock member is adapted to operatively engage the outer layer lock member so as to releasably lock the sun visor into a fixed position. The sun visor lock member and the outer layer lock member operatively engage so as to allow the sun visor to be releasably locked into one of a plurality of fixed positions. the sun visor attachment member and the outer layer attachment member rotatably engage via a snap fit fastener.
Without intending to be limited by theory, it is believed that the improved helmet herein may provide one or more benefits over the prior art helmets having adjustable sun visors. For example, the improved helmet herein may provide an improved attachment member and lock member system which allows easy production and easy adjustment of the sun visor to a plurality of different angles, in a fixed manner. The system herein also allows the sun visor to be fixed in a manner which prevents undesired slippage of the sun visor unless the sun visor is manually adjusted by the user.
The figures herein are for illustrative purposes only and not necessarily drawn to scale.
Unless otherwise specifically provided, all tests herein are conducted at standard conditions which include a room and testing temperature of 25° C., sea level (1 atm.) pressure, pH 7, as appropriate, and all measurements are made in metric units. Furthermore, all percentages, ratios, etc. herein are by weight, unless specifically indicated otherwise.
An improved bicycle helmet includes an inner layer having a concave shape, an outer layer having a convex shape, and a sun visor. The outer layer covers the inner layer and includes an outer layer attachment member and an outer layer lock member. The sun visor contains a shade member, a sun visor attachment member and a sun visor lock member. The sun visor attachment member is connected to and distal from the shade member and is adapted to rotatably engage with the outer layer attachment member to form a fulcrum. The sun visor lock member is adapted to operatively engage to the outer layer lock member so as to releasably lock the sun visor into a fixed position. The sun visor lock member and the outer layer lock member operatively engage so as to allow the sun visor to be releasably locked into one of a plurality of fixed positions. The sun visor attachment member and the outer layer attachment member rotatably engage via a snap fit fastener.
In an embodiment herein, the inner layer may contain and/or be formed of cardboard; or corrugated cardboard, such as found in the Kranium helmet designed by Anirudha Rao (a.k.a., Anirudha Surabhi; see, for example: http://www.geek.com/articles/geek-cetera/kranium-a-cardboard-helmet-thats-safe than-plastic-2011068/) which combines corrugated cardboard with other impact-absorbing and ergonomic materials.
The inner-layer, 12, may include a comfort-enhancing member, 14. The comfort-enhancing member typically touches the user's head in one or more places and may be, for example, a pad, a cushion, a depression, etc. In
In an embodiment the comfort-enhancing member is in the form of a depression which is specifically formed to accommodate a portion of the user's head, such as, for example the ears, or a portion of the head. In some cases, where, for example, the intended user has a more angular head shape as compared to a rounder or oval head shape, such a depression; or multiple depressions; may provide a significantly improved fit and/or comfort.
The comfort-enhancing member may be formed of any useful material known in the art, such as, for example, a plastic, rubber, a foam, cloth, and a combination thereof; or a memory foam, cloth, a porous plastic, rubber and a combination thereof; or a memory foam, cloth, and a combination thereof. Without intending to be limited by theory, it is believed that a memory foam provides improved comfort to the user, while a cloth or a porous plastic provides sweat wicking and breathability properties that enhance the comfort of the user. In an embodiment herein the comfort-enhancing member is inflated with a gas such as air or an inert gas.
In an embodiment herein the comfort-enhancing member may also serve to reduce the amount of impact force transmitted to the user's head and body. Such an impact force reduction may be due to, for example absorption or dissipation of at least a portion of the impact force.
The outer layer, 18, serves multiple purposes such as aesthetics, additional impact dissipation, friction reduction, etc. For example, the outer layer may have various pigments, patterns, ornamentation, and/or textures thereupon or included therein, including those recognizable as designs, logos, etc. In an embodiment herein, the outer layer is a hard, relatively brittle material such as, for example, acrylonitrile butadiene styrene, and/or polycarbonate, which is intended to shatter upon impact so as to further dissipate the impact of a collision. In theory, such a shattering of the outer layer propagates the impact force in a lateral direction, so as to reduce the force transmitted inwardly through the helmet to the inner layer and therefore to the user. A shattered outer layer after an impact may also be an indication that the impact was great enough that the structural integrity of the bicycle helmet may have been compromised, and therefore may serve as an indication that the bicycle helmet should be replaced with a new helmet and/or repaired. Without intending to be limited by theory, it is believed that this may reduce the chance that a helmet with compromised structural integrity is further used so as to result in an avoidable injury.
In an embodiment herein the outer layer contains an outer layer material selected from a polycarbonate, a polystyrene, a polyacrylate and a mixture thereof; or from acrylonitrile butadiene styrene, an extruded polystyrene, an expanded polystyrene, and a mixture thereof; or acrylonitrile butadiene styrene, an expanded polystyrene and a mixture thereof.
In an embodiment herein, the outer layer includes a friction-reducing material selected from polytetraflouroethylene, perfluoroalkoxy, fluorinated ethylene propylene, aluminium magnesium boride, nylon, an acetal, an ultra high molecular weight polyethylene, and a mixture thereof. Such a friction-reducing material may be, for example, coated onto the outer layer or may be mixed into the outer layer material during the moulding process or even earlier in the process, as desired by one skilled in the art.
Methods for forming and manufacturing a bicycle helmet containing an inner layer and outer layer are well known in the art and typically include providing a female mould portion, providing a male mould portion, providing an impact-dissipating material, providing the outer layer material, and optionally providing any separately-made comfort-enhancing members. The female mould portion is complementary to the male mould portion and therefore the female mould portion and the male mould portion are able to be fit together so that they form a hollow mould therebetween. The relevant materials and parts are then added into the mould in the proper order and under the proper conditions to form a helmet. Additional modifications may be further made after the moulding process, such as adding ornamentation, decorations, optional comfort-enhancing materials, logos, etc.
Without intending to be limited by theory it is believed that these fixed positions provide a sufficient number of fixed positions to accommodate the user's needs, while reducing potential confusion by the user when there are too many fixed positions. Such a limited number of fixed positions may also reduce manufacturing complexity, as well as the amount of raw materials needed to form the respective lock members.
In
The visor, 20, also may contain a vent, 22, for passing air, heat, etc. therethrough. When the vent, 22, is on the sun visor, 20, the vent, 20, must be design such that the vent does not allow a significant amount of sunlight through so as to strike the user's eyes. Accordingly, such a vent, 22, in the sun visor, 20, is typically angled or otherwise designed to defeat the purpose of the sun visor, 20. In an embodiment herein the sun visor contains from about 1 vent to about 6 vents; or from about 2 vents to about 4 vents.
The bicycle helmet, 10, of
The bicycle helmet, 10, and the inner layer, 12, also may include additional items such as, for example, a chin strap tab, 24, ear holes (not shown), accessory attachment points, 26, integrally moulded therein, permanently affixed thereto, or removably affixed thereto. The accessory attachment points, 26, may allow, for example, a Bluetooth earphone to be affixed to the bicycle helmet, 10, to allow hands-free communication with others while riding a bicycle.
In
In this embodiment, the outer layer attachment member, 34, and the outer layer lock member, 36, are integrally-formed in a housing, 38, which is typically formed of a single piece of plastic, resin or metal. Such a construction method improves manufacturing efficiency, and may also help to keep manufacturing tolerances between the sun visor and the outer layer more consistent.
In
At each fixed position location, 48, the sun visor, 20, is in a fixed state, meaning that the visor will not move to an adjacent fixed position location without specific adjustment by the user. In the embodiment of
As one skilled in the art would understand an outer layer lock member, 36, could be formed with any number of such fixed position locations, as desired. Furthermore, such an outer layer lock member, 36, could be formed with such fixed position locations positioned such that the angles between such fixed positions are regular or varied, as desired.
The outer layer lock member, 36, also contains a lip, 44, similar to that of the outer layer attachment member, 34. The lip, 44, of the outer layer lock member, 36, engages the sun visor lock member (see
Similarly, when the sun visor is moved in the direction of arrow, C, the sun visor, 20, and the housing, 38, come together such that the sun visor lock member, 60, engages with the outer layer lock member, 36, to form a snap fit fastener. More specifically, in this embodiment the outer layer lock member, 36, is an outer layer structure, 40, containing a socket, 42, that engages the sun visor lock member, 60. The sun visor lock member, 60, contains a sun visor structure, 56, that in turn contains a protrusion, 58, that engages the socket, 42, to allow the sun visor, 20, to be releasably locked into one of a plurality of fixed positions.
In the embodiment of
Such snap fit fasteners, their construction, and the materials therefor are well-known in the art; in an embodiment herein the snap fit fastener is selected from the group consisting of a cylindrical-type snap fit and a spherical-type snap fit. While a cantilever beam snap fit may be technically possible, such a shape typically makes it difficult for the outer layer attachment member to rotatably engage the sun visor attachment member. Furthermore, the structural elements of each side of the snap fit fastener may be formed integrally as a single piece or may be formed individually and subsequently combined, as is known in the art.
Without intending to be limited by theory, it is believed that the use of a snap fit fastener in the present invention possesses many advantages as compared to a screw, bolt, or other fastening method. Specifically, such a snap fit fastener is significantly easier and faster to assemble than other fastening methods. Thus, manufacturing speeds are increased, while production errors and manufacturing complexity are decreased. Further, it is recognized that in many cases the sun visor may become damaged while the remainder of the helmet remains undamaged. In such cases, the user may wish to quickly and easily replace the sun visor with a replacement. Such a snap fit fastener makes such a replacement by the user easy on the road, without the need for tools. In another instance, the user may wish to have different types of sun visors (e.g., different shapes, different tints, opaque/translucent, different colors, etc.) and thus they may wish to often replace or change the sun visor while utilizing the same helmet. The improved bicycle helmet herein provides such advantages.
One skilled in the art will understand that each of the outer layer attachment member and the outer lock member may contain an outer layer structure. Each outer layer structure may be selected from a protrusion, a socket, and a combination thereof, as desired by the designer. However, in such a case, the corresponding sun visor attachment member and the sun visor lock member should contain a complementary sun visor structure selected from a protrusion, a socket, and a combination thereof. Where the outer layer structure contains a protrusion, then the corresponding sun visor structure should be a socket, and visa versa. Where the outer layer structure contains both a protrusion and a socket, then the corresponding sun visor structure should contain a socket and a protrusion, respectively, that engages the complementary outer layer structure. Therefore, one skilled in the art will understand that various similar but related, or even opposite embodiments are contemplated herein. In an embodiment herein the sun visor attachment member includes a sun visor structure selected from a protrusion and a socket. In an embodiment herein, the sun visor lock member includes a sun visor structure selected from a protrusion and a socket. In an embodiment herein, the outer layer attachment member includes an outer layer structure selected from a protrusion and a socket. In an embodiment herein, the outer layer lock member includes an outer layer structure selected from a protrusion and a socket.
Furthermore, for the ease of manufacturing, and to reduce raw material needs, in an embodiment herein the sun visor lock member is proximal to the sun visor attachment member and the outer layer lock member is correspondingly proximal to the outer layer attachment member. In such a case, the outer layer lock member and the outer layer attachment member may be combined into a single housing. In an embodiment herein, the housing is symmetrical with respect to the outer layer lock member and the outer layer attachment member; or the housing is symmetrical; such as along line 4-4 in
In an embodiment herein, the outer layer attachment member contains a plane of symmetry. In an embodiment herein, the sun visor attachment member contains a plane of symmetry. In an embodiment herein, both the outer layer attachment member and the sun visor attachment member contain planes of symmetry; or the same plane of symmetry. Without intending to be limited by theory, it is believed that such a plane of symmetry allows the sun visor to rotate more easily.
In an embodiment herein the maximum sun visor rotation, as measured from a fixed position location, 48, to the most distal fixed position location, 48′ with respect to the fulcrum, 68, is from about 3° to about 90°; or from about 5° to about 50°; or from about 6° to about 45°; or from about 7° to about 25°. Without intending to be limited by theory, it is believed that angles that are too large may cause increased air resistance against the sun visor, which is undesirable, whereas an angle which is too small may not be sufficient adjustment for the user to effectively block the sun at different times and angles.
An optional positioning tab, 70, also helps to align the housing, 38, within a mould, and/or to help prevent slippage of the housing during the manufacturing process. Such a positioning tab may be, for example, an indentation, or a protrusion as desired. In an embodiment herein, the outer layer attachment member; or the outer layer lock member; or the outer layer attachment member and the outer layer lock member; or the housing, is embedded in the outer layer. Such an embedding may be, by, for example, placing the outer layer attachment member; or the outer layer lock member; or the outer layer attachment member and the outer layer lock member; or the housing into the mould during the production process, and then forming the outer layer around it. Alternatively, the outer layer attachment member; or the outer layer lock member; or the outer layer attachment member and the outer layer lock member; or the housing may be embedded into the outer layer after the outer layer is made by, for example adding it to a predetermined spot in the outer layer. Without intending to be limited by theory, it is believed that such an embedded outer layer attachment member; or the outer layer lock member; or the outer layer attachment member and the outer layer lock member; or the housing may reduce drag and appear more sturdy, and therefore be more desirable to a user.
Turning to the embodiment of
In
The sun visor, 20, contains a shade member, 72, which is intended to cast shade over the user's eyes, and a sun visor left arm, 74′″, extending from the shade member, 72. The sun visor left arm, 74′″, contains a sun visor left attachment member, 54′″, connected to and distal from the shade member, 72. Similarly, the sun visor, 20, contains a sun visor right arm, 74″″, extending from the shade member, 72. The sun visor right arm, 74″″, is opposite the sun visor left arm, 74′″, and includes a sun visor right attachment member, 54″″, connected to and distal from the shade member, 72. When the sun visor, 20, is connected to the outer layer, 18, (see the dotted arrows) the outer layer left attachment member, 34′″, rotatably engages with the sun visor left attachment member, 54′″, to form a left fulcrum, and the outer layer right attachment member, 54″″, rotatably engages with the sun visor right attachment member, 34″″ to form a right fulcrum (not shown).
The sun visor left arm, 74′″, also contains a sun visor left lock member, 60′″, and the outer layer left side, 18′″, contains a corresponding outer layer left lock member, 36′″. The sun visor right arm, 74″″, also contains a sun visor right lock member, 60″″, and the outer layer right side, 18″″, contains a corresponding outer layer right lock member, 36″″. When the sun visor, 20, is connected to the outer layer, 18, (see the dotted arrows) the sun visor left lock member, 60′″, operatively engages the outer layer left lock member, 36′″, to releasably lock the sun visor, 20, to allow a plurality of fixed left positions (not shown). When the sun visor, 20, is connected to the outer layer, 18, (see the dotted arrows) the sun visor right lock member, 60″″, operatively engages the outer layer right lock member, 36″″, to releasably lock the sun visor, 20, to allow a plurality of fixed right positions (not shown).
Therefore, one skilled in the art understands that in
Helmet, 10, also contains a vent, 22, in which is embedded a mesh, 76. The mesh, 76, is typically a fine mesh which allows air to flow therethrough to maintain ventilation for the user's head, while simultaneously preventing debris such as insects, leaves, etc. from entering the helmet and bothering the user.
In an embodiment herein, the outer layer attachment member, the outer layer lock member, the sun visor attachment member and the sun visor lock member are independently made from a material selected from a plastic, a resin, rubber, glass, and a combination thereof.
It should be understood that the above only illustrates and describes examples whereby the present invention may be carried out, and that modifications and/or alterations may be made thereto without departing from the spirit of the invention.
It should also be understood that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided or separately or in any suitable subcombination.
Number | Date | Country | Kind |
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13100213.6 | Jan 2013 | HK | national |