Patent Application
20230059228
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.
An illustrative helmet includes an outer shell and an impact absorbing layer adjacent to the outer shell. The helmet also includes a fit system mounted to the impact absorbing layer. The fit system includes a rear portion that includes a rotational mount having a ball and an extension mounted to the ball. The fit system also includes a rear mount that includes a plurality of grooves. Each groove in the plurality of grooves is configured to receive the rotational mount of the rear portion of the fit system.
An illustrative method of making a helmet includes thermoforming a first carbon section for a helmet. The first carbon section includes a first overlap area. The method also includes thermoforming a second carbon section for the helmet. The second carbon section includes a second overlap area. The method also includes aligning the first overlap area with the second overlap area such that there is a gap between the first overlap area and the second overlap area. The method further includes placing an adhesive in the gap to adhere the first carbon section to the second carbon section to form a carbon cage.
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.
Many traditional cycling helmets include a fit system, or yoke, that provides points of contact between the user and the helmet. The fit system may include bands or straps that extend around a circumference of the user’s head and that keep the main body of the helmet from coming into contact with the user’s head. This configuration can also be used to create a space, or air gap, between the user’s head and the main body of the helmet. The air gap enhances air flow, which helps to reduce heat and sweat when the helmet is worn during cycling.
Traditional helmet fit systems are often adjustable such that the helmet is able to fit a range of different head sizes. The adjustable feature allows the circumference of the band/strap/cord that goes around the head of the user to be increased or decreased to a desired size. The adjustment mechanism is often in the form of a laced ratcheting system, such as the BOA® system or similar. This circumference adjustment is generally the only adjustable feature in traditional helmet fit systems. Described herein is a fit system that provides additional adjustment options which help to facilitate a better fit and more comfort for the user. The proposed fit system also provides improved storage options for the helmet, as discussed in more detail below.
In an illustrative embodiment, the impact absorbing layer 110 can be made of expanded polystyrene (EPS). In alternative embodiments, the impact absorbing 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 impact absorbing layer 110 can be formed by blowing, molding, or any other technique known to those of skill in the art. In one embodiment, an inner surface of the outer shell 105 is coated with an adhesive that is used to attach the impact absorbing layer 110 to the outer shell 105.
As shown, the outer shell 105 is formed to include vent openings that form vents 115. The impact absorbing layer 110 also includes vent openings that are aligned with the vent openings in the outer shell 105 to form the vents 115. The vents 115 are included to improve airflow, increase breathability, and reduce the overall weight of the helmet 100.
The helmet 100 also includes a fit system, only a portion of which is shown in the views of
As shown, the rear mount 130 includes three different positions at which the rear portion 120 of the fit system can be mounted. In alternative embodiments, a different number of positions may be used, such as one, two, four, six, etc. These adjustable positions allow the rear portion 120 of the fit system to be raised or lowered relative to the interior of the helmet 100 (i.e., relative to the impact absorbing layer 110). The adjustments allow the user to control the position of the fit system on his/her head, which allows the user to achieve a more comfortable fit.
As best shown in the close up view of
Each of the grooves 135 in the rear mount 130 is in the form of a curved channel that includes a first portion 155, a second portion 160, and a third portion 165 that are fluidly connected to one another and that approximate the shape of a backwards ‘S’. The first portion 155 of the groove 135 extends substantially parallel to a line that extends from the front of the helmet to the back of the helmet. The second portion 160 of the groove 135 extends substantially perpendicular to a line that extends from the front of the helmet to the back of the helmet (i.e., the second portion 160 is substantially perpendicular to the first portion 155). The third portion 165 of the groove 135 extends substantially parallel to a line that extends from the front of the helmet to the back of the helmet (i.e., the third portion 165 is substantially parallel to the first portion 155 and substantially perpendicular to the second portion 160).
The ball 145 on the rotational mount 140 of the rear portion 120 of the fit system rests within the third portion 165 of the groove 135 and enables the rear portion 120 to pivot up or down. Specifically, the curved channel enables multiple positions for the rotational mount 140. For example, in a first position, the extension 150 of the rotational mount 140 is oriented so that the rear portion 120 of the fit system extends downward from the bottom of the helmet. In a second position, the extension 150 of the rotational mount 140 is oriented so that the rear portion 120 of the fit system is elevated and does not drop below a bottom of the helmet.
In traditional helmets, the fit system is stationary and extends down from the main body of the helmet. As a result, when the helmet is set onto a flat surface, the bulk of the helmet presses down on the fit system, which can cause the fit system to warp and bend. If the helmet is stored in such a way for long periods of time, the fit system may become permanently warped/bent, which can adversely affect the comfort of the helmet. As discussed, the ability of the rear portion 120 of the fit system to rotate upward prevents the helmet from resting on the fit system during storage on a flat surface, which eliminates the potential for warping or bending of the fit system.
The front portion 125 of the fit system is mounted to the impact absorbing layer 110 via an embedded mushroom plug 170. In alternative embodiments, a different method of mounting the front portion 125 of the fit system may be used such as an adhesive, rivet, etc.
In the fit systems of traditional helmets, the cord is statically mounted to the front and rear portions of the fit system and is not adjustable. Conversely, in the helmet 100 described herein, the position of the cord is adjustable, which provides further adjustability of the helmet for the user. As shown, the track 175 of the front portion 125 of the fit system includes a first track path 180 and a second track path 185. By running the cord through the first track path 180, the user is able to raise the position of the cord/lace relative to the user’s ears. By running the cord through the second track path 185, the user is able to lower the position of the cord/lace relative to the user’s ears. This adds additional flexibility to the helmet and allows it to be comfortable and functional for a wider range of users, as compared to traditional helmets. Regardless of which track path is used (i.e., either the first track path 180 or the second track path 185), the cord also runs through a main portion of the track 175.
In an illustrative embodiment, each side of the helmet has multiple track paths such that the cord of the fit system can be uniformly adjusted on each side of the helmet. The position of the multiple track paths can be on two terminal ends of the front portion of the fit system, as shown. When the helmet is worn, the multiple track paths can be positioned on the sides of the user’s head, in between the ears and forehead. Alternatively, a different position may be used for the multiple track paths. For example, the multiple track paths may be positioned elsewhere in the front portion 125 of the fit system, or alternatively in the rear portion 120 of the fit system. Also, the depiction of
In another illustrative embodiment, the outer shell of the helmet can be in the form of a carbon cage that is formed through a thermoforming process. In some embodiments, at least a portion of this carbon cage is covered by EPS (or other) material, and the EPS or other impact absorbing material and the carbon cage form the outer shell of the helmet in combination. Traditional outer shells are often in the form of polycarbonate. The use of carbon allows for a lighter shell that is strong and durable. The thermoforming process was found to be an effective way to form the carbon cage. However, creation of a full 360° carbon cage cannot be done in a single form because, once cooled, it would be impossible to remove the formed carbon cage from the form without destroying the form (which is prohibitively expensive). The proposed carbon cage is thus formed in two or more pieces that are adhered to one another after being thermoformed.
Specifically, sections of the carbon cage are formed such that they overlap one another. An engineered gap is formed at each of the overlap areas to accommodate an adhesive, such as pressure sensitive tape, pressure sensitive foam tape, liquid adhesive such as glue or super glue, two part epoxy resin, etc. For example, a gap of ‘x’ millimeters (mm) may be used to accommodate an adhesive having a thickness of ‘x’ mm, where ‘x’ can be any value such as 0.1 mm, 0.3 mm, 0.5 mm, 0.75 mm, 1 mm, 1.5 mm, etc. depending on the adhesive used.
Referring specifically to the figures,
In an operation 305, heat is applied to the carbon pieces that were cut out of the carbon sheet. The heat is part of a thermoforming process and can be applied by placing the carbon pieces into an oven, or by any other technique. The applied heat makes the carbon pieces more pliable so that they can be manipulated and positioned in a form. In an operation 310, the carbon pieces are placed into a two-part forming machine (or form). The two-part forming machine can include a positive side and a negative side. Specifically, the first carbon piece can be placed into a first part (or form) of the two-part forming machine and the second carbon piece can be placed into a second part (or form) of the two-part forming machine.
In an operation 315, the carbon pieces are pressed into a helmet shape. In an illustrative embodiment, the two-part forming machine applies heat and pressure (e.g., hydraulic pressure and/or pneumatic pressure) to press the sides of the form together, which in turn thermoforms the carbon pieces into the desired shapes to form the helmet. As discussed herein, the carbon pieces are formed such that there are areas of overlap between the carbon pieces. Additionally, the pieces are formed such that a gap is formed between the carbon pieces at the areas of overlap. The width of this gap is controlled to accommodate an adhesive of a desired thickness. In an operation 320, heat and pressure are applied to the formed carbon pieces to cure resin in the carbon pieces into a hard form. This ensures that the carbon pieces will retain their formed shape upon removal from the form.
In an operation 325, the formed carbon pieces are removed from the forming machine. A user (or associated computing system) can then measure and analyze the carbon pieces to ensure that the formed pieces are of the correct shape and dimensions. In an operation 330, the first carbon piece is placed into an injection mold. In an operation 335, adhesive is applied to the first carbon piece in the injection mold. The adhesive is applied to the areas of overlap between the first and second carbon pieces. Additionally, the thickness (or depth) of the adhesive is controlled to match a thickness of the gap formed in between the carbon pieces at the areas of overlap. In an operation 340, the second carbon piece is placed into the injection mold.
In an operation 345, additional helmet components are placed into the injection mold. The additional helmet components can include mushroom plugs, mounts for the fit system, etc. In an operation 350, pre-expanded EPS (expanded polystyrene) is injected into the injection mold to complete formation of the helmet. In an illustrative embodiment, any of the operations of
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.
