Patent Application
20190116909
A cycling helmet is often worn by bicyclists as a safety precaution. Traditional helmets utilize a stiff foam material such as expanded polystyrene (EPS) surrounded by a rigid shell to help reduce the peak energy of an impact. Traditional helmets also utilize an adjustable strap system such that the helmet can be securely fastened to the user's head. Additionally, some helmets include foam padding in various areas to improve comfort and prevent chafing.
A cycling helmet comprises an outer shell and a closed cell foam layer adjacent to the outer shell. The cycling helmet also includes an inner liner adjacent to the closed cell foam layer. The cycling helmet further includes an insert of energy absorbing material adjacent to the inner liner. The insert is configured to move in multiple directions in response to an impact to the cycling helmet.
A method of making a cycling helmet includes forming an outer shell. The method also includes forming an inner liner, and mounting a closed cell foam layer between an inner surface of the outer shell and an outer surface of the inner liner. The method further includes placing an insert of energy absorbing material adjacent to an inner surface of the inner liner. The insert is configured to move in multiple directions in response to an impact to the cycling helmet.
Other principal features and advantages of the invention will become apparent to those skilled in the art upon review of the following drawings, the detailed description, and the appended claims.
Illustrative embodiments will hereafter be described with reference to the accompanying drawings, wherein like numerals denote like elements. The foregoing and other features of the present disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several embodiments in accordance with the disclosure and are, therefore, not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through use of the accompanying drawings.
Traditional cycling helmets often utilize a stiff foam material, such as EPS, to absorb all of the impact in the event of an accident. The impact absorbed by the helmet during an accident can include both direct impact and rotational or oblique impact. During a direct impact in which the helmet contacts an object straight on, the EPS can often effectively absorb the contact and prevent injury to the user due to the (irreversible) compressibility of the EPS. However, during a rotational/oblique impact in which the helmet slides along, rolls along, or glances off an object, traditional EPS helmets are sometimes unable to fully absorb the impact, resulting in a higher likelihood of injury. One reason for the higher likelihood of injury during a rotational impact is that traditional EPS inserts are statically mounted within a shell and are unable to move with the user's head during such impact. As a result, the user's head movement is restricted during an accident, and it is possible that axons in the brain can stretch and/or tear during the rotational/oblique impact.
Described herein is a cycling helmet that utilizes an insert made from energy absorbing material with multi-directional flexibility. The energy absorbing material, which can be made from polycarbonate or a similar material, is able to bend, compress, stretch, and shift in multiple directions without shearing. As discussed herein, the energy absorbing material is maintained in a largely spherical shape within a shell of the helmet such that the material retains its ability to bend, compress, stretch, and shift in multiple directions.
The outer shell 105 of the cycling helmet 100 can be made from plastic, resin, fiber, polycarbonate, polyethylene, terephthalate (PET), acrylonitrile butadiene styrene, polyethylene (PE), polyvinyl chloride (PVC), vinyl nitrile (VN), fiberglass, carbon fiber, or other similar material. In addition to housing other components of the cycling helmet 100, the outer shell 105 provides a rigid outer layer. Depending on the implementation, the outer shell 105 can be formed through stamping, molding, vacuum forming, or any other known fabrication technique. The outer shell 105 is formed to include vent openings that form vents 130. The vents 130 are included to improve airflow, increase breathability, and reduce the overall weight of the cycling helmet 100.
Adjacent to the outer shell 105 is the closed cell foam layer 110. In an illustrative embodiment, an inner surface of the outer shell 105 is coated with an adhesive that is used to attach the closed cell foam layer 110 to the outer shell 105. Any type of suitable adhesive may be used. The closed cell foam layer 110 can be formed by blowing, molding, or any other technique known to those of skill in the art. In another illustrative embodiment, the closed cell foam layer 110 can be made of expanded polystyrene (EPS). In alternative embodiments, the closed cell foam layer 110 can be made of one or more layers of the same or similar materials, including an impact energy absorbing material such as expanded polypropylene (EPP), expanded polyurethane (EPU), vinyl nitrile (VN), or any other material that absorbs impact energy through deformation. The closed cell foam layer 110 also includes vent openings that are aligned with the vent openings in the outer shell 105 to form the vents 130. In an illustrative embodiment, the vent openings on the interior side of the closed cell foam layer 110 are chamfered to allow an energy absorbing insert in the cycling helmet to move relative to the vent openings without being restricted by them. The chamfered edges of the closed cell foam layer 110 are depicted and described in more detail with reference to
The straps 125 of the cycling helmet 100 are used to secure the cycling helmet 100 to a user's head. Any type of adjustable helmet strap may be used. In an illustrative embodiment, the straps 125 include a first strap attached a left side of the cycling helmet 100 and a second strap attached to the right side of the cycling helmet 100. The first strap and second strap are configured to be connected to one another under a user's chin by way of a buckle or clip as known to those of skill in the art. In an illustrative embodiment, the straps 125 are integrated into the fit system 115 that includes the yoke 120 and other components. In an alternative embodiment, the straps 125 may be independent of the yoke 120. The fit system 115 and its components are described in more detail below.
The insert 205 of energy absorbing material is maintained within a largely spherical shape within the cycling helmet 200 such that the insert 205 covers at least a portion of the top, front, and rear of a user's head.
Referring again to
An inner side of the inner liner 210 includes an inner liner coating. In an illustrative embodiment, the inner liner coating is a paint that provides a low friction (or slippery) surface for the insert 205 to rest upon. In an alternative embodiment, the inner liner coating may be a powder coat or other low friction substance other than paint. The low friction surface of the inner liner coating enables the insert 205 of energy absorbing material to bend, compress, stretch, and/or otherwise shift in the event of an impact to the cycling helmet 100. Chamfered edges on the vent openings of the inner liner 210 also help facilitate the movement of the insert 205 such that binding of the insert 205 does not occur at the vent openings. In an alternative embodiment in which the inner liner 210 is formed from a low friction material, the inner liner coating may not be used.
As depicted in
Depending on the type of material used for the insert 205 of energy absorbing material, the interior edges of the insert 205 may be somewhat abrasive and uncomfortable if in direct contact with skin. An insert cover 220 is used to cover a portion of the inner edge of the insert 205 that is adjacent to the shelf 215. More specifically, the insert cover 220 covers a portion of the closed cell foam layer 110 that is adjacent to the shelf 220 and a portion of an interior surface of the insert 205. In an illustrative embodiment, the insert cover 220 traverses the entire interior perimeter of the cycling helmet 200 to add comfort and protect the user's head from an abrasive surface that may be found on the insert 205. In addition to adding comfort, the insert cover 220 also helps keep the insert 205 in place and helps prevent its removal.
In an illustrative embodiment, the insert cover 220 is formed from polycarbonate. Alternatively, the insert cover 220 may be made of a different material. In another illustrative embodiment, the insert cover 220 can be attached to the fit system 115 and can be mounted to the cycling helmet 200 by way of anchors that are attached to the closed cell foam layer 110 using mushroom plugs. This configuration is depicted and described in more detail with reference to
As depicted in
In an illustrative embodiment, the insert cover 220 depicted in
As depicted in
Referring again to
As discussed above, the cycling helmet can include straps, such as the straps 455 depicted in
In an operation 805, an inner liner for the cycling helmet is formed. In an illustrative embodiment, the inner liner is formed as a thin layer of a rigid substance such as polycarbonate. Alternatively, other materials may be used. Similar to the outer shell, the inner liner may be formed by heating and pressure molding a sheet of material into the appropriate shape, and then cutting vent openings into the molded unit. In another illustrative embodiment, the vent openings of the inner liner can have a chamfered edge that matches the chamfered edges of the vent openings formed in the closed cell foam layer. In alternative embodiments, different materials and/or a different process may be used to form the inner liner.
In an operation 810, an inner liner coating is applied to an inner surface of the inner liner. The inner liner coating can be a paint that provides a low friction (or slippery) surface for the insert to rest upon. Alternatively, the inner liner coating may be a powder coat or other low friction substance. The low friction surface of the inner liner coating helps allow the insert of energy absorbing material to bend, compress, stretch, and/or shift in the event of an impact. In an alternative embodiment in which a surface of the inner liner is sufficiently slippery on its own, an inner liner coating may not be applied. In one embodiment, the inner liner coating may be applied to the material used to form the inner liner prior to the actual formation of the inner liner.
In an operation 815, a closed cell foam layer is mounted between the outer shell and the inner liner. In an illustrative embodiment, the closed cell foam layer can be made from pre-expanded EPS that is co-molded (or injection molded) with the outer shell and the inner liner in a mold. In such an implementation, the closed cell foam layer is formed and mounted to the cycling element during the injection molding process. In an alternative embodiment, the closed cell foam layer may be formed independent of the outer shell and the inner liner. In such an embodiment, the closed cell foam layer is mounted to the cycling helmet using an adhesive, fasteners, and/or any other techniques. In alternative embodiments, a different material and/or fabrication process may be used. In another illustrative embodiment, the closed cell foam layer is molded to include a shelf to support an insert, vent openings, and a chamfered edge that surrounds the vent openings along the interior surface of the layer. The closed cell foam layer can also be molded such that anchors are incorporated therein to receive a fit system and an insert cover as described herein. The closed cell foam layer can further be molded to include an inset to receive a portion of the insert cover such that the insert cover can be mounted flush with the interior surface of the closed cell foam layer.
In an operation 820, an insert for the cycling helmet is formed. The insert can be formed by molding, cutting from a sheet of material, or by any other fabrication process known in the art. In an illustrative embodiment, the insert can be made of plastic, resin, fiber, polycarbonate, polyethylene, terephthalate (PET), acrylonitrile butadiene styrene, polyethylene (PE), polyvinyl chloride (PVC), vinyl nitrile (VN), fiberglass, carbon fiber, aluminum, or any other suitable material. As discussed above, the insert is able to bend, compress, stretch, and shift in multiple directions without shearing. The insert can be a solid material, or in the form of a honeycomb with openings that facilitate the bending, compression, stretching, and/or shifting of the material. Formation of the insert can also include incorporating openings in the insert through which mushroom plugs or other fasteners can be passed to secure the insert cover to the anchors molded into the closed cell foam layer. Formation of the insert can also include forming an inset in an interior surface of the insert that is configured to receive a portion of an insert cover. In an illustrative embodiment, the insert is formed such that it does not include vent openings such as those present in the outer shell and the closed cell foam layer. In an alternative embodiment, the insert may be formed to include such vent openings which align with those in the outer shell and the closed cell foam layer.
In an operation 825, the insert is placed into the cycling helmet. In an illustrative embodiment, the insert is positioned such that the insert is adjacent to and follows the contour of coated inner liner. The insert is also positioned such that a bottom edge of the insert rests upon the shelf formed in the closed cell foam layer, as described herein.
In an operation 830, an insert cover is mounted to the closed cell foam layer such that the insert cover covers an interior interface between the insert and the shelf formed in the closed cell foam layer. In an illustrative embodiment, the insert cover is mounted such that it is received by insets formed in both the closed cell foam layer and the insert. As a result, the mounted insert cover is flush with both the insert and the closed cell foam layer along the aforementioned interior interface between those components. The insert cover can be mounted via mushroom plugs or other fasteners which connect the insert cover to the anchors molded into the closed cell foam layer.
In an operation 835, a yoke of a fit system is mounted to the insert cover using mushroom plugs or other fasteners. In an illustrative embodiment, the yoke includes a mounting strap that is configured to be received by a receiving strap attached to the insert cover. In alternative embodiments, a different method for mounting the fit system to the cycling helmet may be used.
The word “illustrative” is used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “illustrative” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Further, for the purposes of this disclosure and unless otherwise specified, “a” or “an” means “one or more”.
The foregoing description of illustrative embodiments of the invention has been presented for purposes of illustration and of description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The embodiments were chosen and described in order to explain the principles of the invention and as practical applications of the invention to enable one skilled in the art to utilize the invention in various embodiments and with various modifications as suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents.
The present application claims the priority benefit of U.S. Provisional Patent App. No. 62/574,370 filed on Oct. 19, 2017, the entire disclosure of which is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 62574370 | Oct 2017 | US |
