Patent Grant
11812815
The subject matter disclosed herein relates to an in-molded helmet chinbar for a protective helmet, such as helmets used in motocross, other motorsports or protective helmets such as being used in downhill bicycling sports.
Protective helmets are frequently used for recreational and vocational activities and sports. For example, protective helmets are used as head protection in motorsports, by jockeys in horse racing, in American football, ice hockey games, cricket games, and during rock climbing. Protective helmets are also used when performing dangerous work activities, such as hard hats used in construction work, during mining activities, and by police agents. Protective helmets are often required to be worn in transportation, for example motorcycle helmets and bicycle helmets.
The subject matter disclosed herein offers solutions for problems resulting from unitary construction of a chinbar and helmet.
One embodiment relates to a helmet. The helmet includes a shell, a padding, and a chinbar. The shell has an exterior surface and an interior surface. The padding is disposed along the interior surface of the shell. The padding defines a first engagement surface positioned at a first lateral side of the padding and a second engagement surface positioned at an opposing second lateral side of the padding. The chinbar includes a cage, a first flange, and a second flange. The cage is configured to extend around a chin of a wearer of the helmet. The cage includes a first end defining a third engagement surface and a second end defining a fourth engagement surface. The third engagement surface of the chinbar interfaces with the first engagement surface of the padding and the fourth engagement surface of the chinbar interfaces with the second engagement surface of the padding. The first flange extends from the first end of the cage. The second flange extends from the second end of the cage. The first flange of the chinbar is embedded within the first lateral side of the padding and the second flange of the chinbar is embedded within the opposing second lateral side of the padding.
Another embodiment relates to a helmet chinbar. The helmet chinbar includes a cage, a first attachment member, and a second attachment member. The cage is configured to extend around a chin of a wearer of a helmet. The cage includes a first attachment end and a second attachment end. The first attachment member includes a first plate that extends from the first attachment end of the cage. The second attachment member includes a second plate that extends from the second attachment end of the cage. The first plate and the second plate of the helmet chinbar are configured to embed within a padding of the helmet to attach the cage to the helmet. The first plate and the second plate increase in at least one of height and thickness along a length thereof.
Yet another embodiment relates to a helmet. The helmet includes a shell, a padding, and a chinbar. The shell has an exterior surface and an interior surface. The padding is disposed along the interior surface of the shell. The chinbar includes a cage, a first attachment member, and a second attachment member. The cage is configured to extend around a chin of a wearer of the helmet. The cage includes a first attachment end and a second attachment end. The first attachment member extends from the first attachment end of the cage. The second attachment member extends from the second attachment end of the cage. The first attachment member and the second attachment member of the chinbar are embedded within the padding.
Still another embodiment relates to a method of manufacturing a helmet. The method includes forming a chinbar of the helmet in a first forming operation, the chinbar including a pair of flanges; forming a shell of the helmet in a second forming operation; coupling the chinbar to the helmet shell such that the pair of flanges extend within an internal cavity of the helmet shell; and in-molding a padding layer into the internal cavity of the helmet shell such that the pair of flanges of the chinbar become embedded within the padding layer.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
The drawings are provided to illustrate example embodiments described herein and are not intended to limit the scope of the disclosure. Throughout the drawings, reference numbers may be re-used to indicate general correspondence between referenced elements.
Various aspects of the disclosure will now be described with regard to certain examples and embodiments, which are intended to illustrate but not to limit the disclosure. Nothing in this disclosure is intended to imply that any particular feature or characteristic of the disclosed embodiments is essential. The scope of protection is defined by the claims that follow this description and not by any particular embodiment described herein. Before turning to the figures, which illustrate example embodiments in detail, it should be understood that the application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.
Embodiments herein generally relate to an in-molded or co-molded helmet chinbar. Such an in-molded helmet chinbar may be used in a number of activities, including without limitation: sports and athletics, including extreme sports such as motocross, snowmobiling, snowboarding, skiing, skateboarding, etc., and traditional sports such as football, hockey, baseball, lacrosse, etc.; cycling activities, including auto racing, motorcycle riding and racing, BMX, mountain biking, downhill biking, etc.; with recreational vehicles including all-terrain vehicles (ATVs), utility task vehicles (UTVs), dirt bikes, snowmobiles, and other off-road vehicles; military and/or construction applications; to name just a few. Further details are provided herein.
Typical helmet construction consists of a shell having a generally dome-shape structure which covers most of the user's head and having a view area or opening at the front. Helmets often include a chinbar to protect a wearer of a helmet during impacts to the face and/or head. Chinbars are traditionally integrally formed with a shell of the helmet (e.g., a unitary construction). Such a unitary construction may lead to several disadvantages including increasing the overall weight of the helmet, preventing the implementation of chinbar ventilation, and reducing impact absorption performance.
According an exemplary embodiment, a helmet (e.g., a full-face helmet, etc.) includes a shell, a padding, and a chinbar. The chinbar may be manufactured from a first material (e.g., Kevlar, carbon fiber, aramid fiber, fiberglass, polycarbonate, acrylonitrile butadiene styrene (ABS), etc.). The shell may be manufactured from a second material (e.g., Kevlar, carbon fiber, aramid fiber, fiberglass, polycarbonate, ABS, etc.). The padding may be manufactured from a third material (e.g., a compressible, impact attenuating polymeric material, etc.). The padding is configured to be received within an interior of the helmet and conform to the head of a wearer of the helmet. The chinbar may include a cage, a first attachment member, and a second attachment member. The cage is configured to extend around a chin of a wearer of the helmet. According to an exemplary embodiment, the chinbar is an individual, unitary component of the helmet (e.g., the chinbar is not integrally formed with the shell, etc.). The first attachment member and the second attachment member of the chinbar are configured to be embedded within the padding to attach the cage to the helmet (e.g., the chinbar is in-molded or co-molded within the padding of the helmet, etc.), according to an exemplary embodiment. In some embodiments, the cage defines a plurality of apertures forming open space within the cage, thereby reducing an overall weight of the helmet and increasing ventilation through the chinbar and into the internal cavity of the helmet. The exemplary helmet including the in-molded chinbar of the present disclosure provides various advantages over other designs, such as a traditional helmet including a unitary shell and chinbar structure. The advantages may include, but are not limited to, reducing the overall weight of the helmet and/or chinbar (e.g., facilitating a lightweight construction, etc.), and increasing ventilation, while still satisfying various helmet impact standards (e.g., ASTM F1952, etc.).
According to the exemplary embodiment shown in
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In one embodiment, the padding 40 is configured as a multi-layer padding (e.g., has two or more layers, etc.). The layers of the padding 40 may be configured to cooperatively provide impact resistance to mitigate (e.g., reduce, lessen, absorb, dissipate, attenuate, etc.) an impact force experienced by the exterior surface 24 of the helmet shell 20 as the impact force propagates through the multiple layers of the padding 40. By way of example, the padding 40 may include a first, outer layer (e.g., disposed along the interior surface 26 of the helmet shell 20, etc.) and a second, inner layer (e.g., configured to conform to the head of a wearer of the helmet 10, etc.). In one embodiment, the outer layer and the inner layer are manufactured from the same material. In other embodiments, the outer layer is manufactured from a first material and the inner layer is manufactured from a second, different material. In some embodiments, the outer layer has a first density and the inner layer has a second, different density. In one embodiment, the first density of the outer layer is relatively greater (e.g., more dense, etc.) than the second density of the inner layer. In other embodiments, the first density of the outer layer is relatively equal to or less than the second density of the inner layer. In some embodiments, the outer layer and the inner layer defines interlocking profiles that facilitate progressive (e.g., analog, etc.) impact resistance. The interlocking profiles may include continuous and/or discrete protrusions (e.g., continuous wedges, conical protrusions, etc.) that interface with one another.
In some embodiments, the padding 40 and/or the helmet shell 20 include reinforcement members (e.g., titanium reinforcement members, titanium rings, etc.) positioned around the periphery of the internal cavity 12 or portions thereof. As shown in
As shown in
In some embodiments, the visor 70 is pivotally coupled to the upper, front surface 38 of the helmet 10. For example, the visor 70 may pivot around the sides of the helmet 10 at an angle relative to a horizontal plane. The angle may range, for example, anywhere between −90 degrees to +270 degrees relative to the horizontal plane of the helmet 10. In some embodiments, the visor 70 may be adjustable within a limited range, for example, ranging between −45 and +45 degrees relative to the horizontal plane. In some embodiments, the visor 70 is coupled to the helmet shell 20 with at least one of a breakaway connection and a toolless, pivotable connection. By way of example, the visor 70 may be coupled to the helmet shell 20 with one or more coupling elements (e.g., magnets, hook and loop fasteners, clips, etc.) that allow the visor 70 to decouple (e.g., break-away, etc.) from the helmet shell 20 during an impact to the visor 70 (e.g., during a crash, etc.). In some embodiments, the visor 70 is manufactured from an elastic and/or soft material that allows the visor 70 to deform during an impact to the visor 70 (e.g., during a crash, etc.). In another embodiment, the visor 70 is integrally formed with the helmet shell 20. In other embodiments, the helmet 10 does not include the visor 70.
As shown in
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According to an exemplary embodiment, the chinbar 100 is an individual, unitary component of the helmet 10. As shown in
According to an exemplary embodiment, the chinbar 100 is configured to protect a wearer's face (e.g., from debris, during an impact, etc.) and/or mitigate at least a portion of impact energy experienced by the chinbar 100 during an impact thereto. In some embodiments, the chinbar 100 is configured to deform to absorb such impact energy and then return to its original shape (e.g., elastic behavior, including a resilient material such as polycarbonate, etc.). In some embodiments, the chinbar 100 is configured to deform to absorb such impact energy and then shatter at some point (e.g., an impact threshold, a deformation threshold, plastic behavior, including a stiff material such as carbon fiber, etc.).
As shown in
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According to the exemplary embodiment shown in
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According to an exemplary embodiment, the cage 110 defines a plurality of apertures forming open space within the chinbar 100, thereby reducing an overall weight of the chinbar 100 and the helmet 10, as well as increasing ventilation through the chinbar 100 into the internal cavity 12 of the helmet 10. Such a reduction in weight may be beneficial for various applications to provide a lightweight helmet (e.g., downhill biking, motocross, etc.). As shown in
According to the exemplary embodiment shown in
According to an exemplary embodiment, the vents (e.g., the right cage vent 122, the left cage vent 132, the central cage vent 142, the central cage vents 144, etc.) of the chinbar 100 include open space or open area that accounts for a majority of the chinbar 100 (e.g., the open space accounts for greater than 50% of the volume of the cage 110; greater than 50% of the surface area of the exterior 112 of the cage 110 is removed to form open space; any sub-range between 50% and 95% or any sub-value therebetween; as much as manufacturing allows; without affecting the structural integrity of the chinbar 100; etc.). In one embodiment, the chinbar 100 includes about 50%-95% open space or open area. In another embodiment, the chinbar 100 includes about 0%-50% open space or open area. In an alternative embodiment, chinbar 100 does not include open space or open area. Therefore, the vents of the chinbar 100 may cover, for example, anywhere from 0% to 95% of the cage 110, including any sub-value or sub-range therein (e.g., 5%, 20%, 40%, 50%, 60%, 70%, 75%, 90%, or any sub-range bound by the same, etc.), In some embodiments, one or more of the vents of the chinbar 100 (e.g., the right cage vent 122, the left cage vent 132, the central cage vent 142, the central cage vents 144, etc.) are formed from and/or include a mesh material (e.g., wire mesh, etc.) positioned to prevent debris (e.g., dirt, rocks, etc.) from entering into the internal cavity 12 of the helmet 10 through the vents of the chinbar 100.
According to various embodiments, the chinbar 100 is manufactured from, but is not limited to, a lightweight plastic, a plastic composite, Kevlar, carbon fiber, aramid fiber, fiberglass, polycarbonate, and/or ABS, among other possible materials. According to an exemplary embodiment, the unitary structure of the chinbar 100 facilitates manufacturing the chinbar 100 independent of the helmet shell 20 and/or the padding 40 with rigidity and a lower overall weight (e.g., due to the vents, the embedded flanges, the ability to independently select a desired material, the ability to optimize thickness and other dimensioning, etc.). According to an exemplary embodiment, the unitary structure of the chinbar 100 facilitates manufacturing the chinbar 100 from a material that is different than the material of at least one of the helmet shell 20 and the padding 40. In one embodiment, the material of the chinbar 100 is different than the material of the helmet shell 20 and the material of the padding 40 (e.g., the chinbar 100 is manufactured from a material that is unique to the helmet 10, etc.). In other embodiments, the material of the chinbar 100 and the material of the helmet shell 20 are the same.
According to an exemplary embodiment, the unitary structure of the chinbar 100 facilitates manufacturing the right portion 120 (e.g., the right padding engagement surface 124, etc.), the left portion 130 (e.g., the left padding engagement surface 134, etc.), and/or of the central portion 140 of the cage 110 with a different size (e.g., thickness, width, dimensions, etc.) than at least one of the helmet shell 20 and the padding 40 (e.g., the right chinbar engagement surface 52, the left chinbar engagement surface 62, etc.). For example, the unitary structure of the chinbar 100 may allow the helmet shell 20 to be relatively thin (e.g., relative to the cage 110, the padding 40, further reducing the weight of the helmet 10, etc.). Further, the cage 110 may be thicker than the helmet shell 20 and/or the padding 40 to increase impact absorption ability of the chinbar 100 and the helmet 10 as a complete unit. Therefore, the chinbar 100 being an individual component of the helmet 10 may facilitate reducing the overall weight of the helmet 10 (e.g., a lightweight construction, etc.), increasing ventilation, and satisfying and/or exceeding various helmet impact standards (e.g., ASTM F1952, etc.).
In some embodiments, the chinbar 100 has different thicknesses (e.g., a variable thickness, etc.) along the cage 110. For example, the central portion 140 and/or the frontal portions of the right portion 120 and the left portion 130 may have a different thickness than the rear portions of the right portion 120 and the left portion 130. For example, the front portions may have a first thickness or density to facilitate absorbing greater impacts, while the rear portions may have a second thickness or density for increased stability between the attachment of the helmet shell 20, the padding 40, and the chinbar 100. In some embodiments, the right portion 120, the left portion 130, and/or the central portion 140 of the cage 110 form hollow tubular sections of the chinbar 100 (e.g., the cage 110 is hollow, an air gap is formed between the exterior 112 and the interior 114 of the cage 110, etc.).
According to the exemplary embodiment shown in
As shown in
In one embodiment, embedding the right flange 150 and/or the left flange 160 within the padding 40 includes molding (e.g., over-molding, etc.) the padding 40 around and/or over the right flange 150 and/or the left flange 160 of the chinbar 100. In another embodiment, embedding the right flange 150 and/or the left flange 160 within the padding 40 includes inserting the right flange 150 and/or the left flange 160 through apertures or slots defined by the right chinbar engagement surface 52 and/or the left chinbar engagement surface 62 of the padding 40, respectively.
As shown in
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It should be noted that the order in which
For example, a method of manufacturing the helmet 10 may be as follows, First, the chinbar 100 of the helmet 10 is formed in a first forming operation. Second, the helmet shell 20 of the helmet 10 is formed in a second forming operation. Third, the chinbar 100 is coupled to the helmet shell 20 such that the right flange 150 and the left flange 160 extend within the internal cavity 12 of the helmet shell 20. Fourth, the padding 40 is in-molded (e.g., injected, shot, etc.) within the internal cavity 12 of the helmet shell 20 such that the right flange 150 and the left flange 160 of the chinbar 100 become embedded within the padding 40. In an alternative embodiment, the padding 40 is over-molded onto the chinbar 100 (e.g., over the right flange 150 and the left flange 160, etc. and then the padding 40 is inserted into the internal cavity 12 of the helmet shell 20.
It is important to note that the construction and arrangement of the elements of the systems, methods, and apparatuses as shown in the exemplary embodiments are illustrative only. Although only a few embodiments of the present disclosure have been described in detail, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements. It should be noted that the elements and/or assemblies of the enclosure may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations.
Embodiments have been described in connection with the accompanying drawings. However, it should be understood that the figures are not drawn to scale. Distances, angles, shapes, etc. are merely illustrative and do not necessarily bear an exact relationship to actual dimensions and layout of the articles that are illustrated. In addition, the foregoing embodiments have been described at a level of detail to allow one of ordinary skill in the art to make and use the articles, parts, different materials, etc. described herein. A wide variety of variation is possible. Articles, materials, elements, and/or steps can be altered, added, removed, or rearranged. While certain embodiments have been explicitly described, other embodiments will become apparent to those of ordinary skill in the art based on this disclosure.
Conditional language used herein, such as, among others, “can,” “could,” “might,” “may,” “e.g.,” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or states. Thus, such conditional language is not generally intended to imply that features, elements and/or configurations are in any way required for one or more embodiments. The terms “comprising,” “including,” “having,” and the like are synonymous and are used inclusively, in an open-ended fashion, and do not exclude additional elements, features, acts, operations, and so forth. The term “consisting essentially of” can be used anywhere where the terms comprising, including, containing or having are used herein, but consistent essentially of is intended to mean that the claim scope covers or is limited to the specified materials or steps recited and those that do not materially affect the basic and novel characteristic(s) of the claimed invention. Also, the term “consisting of” can be used anywhere where the terms comprising, including, containing or having are used herein, but consistent of excludes any element, step, or ingredient not specified in a given claim where it is used.
Also, the term “or” is used in its inclusive sense (and not in its exclusive sense) so that when used, for example, to connect a list of elements, the term “or” means one, some, or all of the elements in the list. Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, and/or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require at least one of X, at least one of Y, and at least one of Z to each be present.
Additionally, in the subject description, the word “exemplary” is used to mean serving as an example, instance, or illustration. Any embodiment or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments or designs. Rather, use of the word exemplary is intended to present concepts in a concrete manner. Accordingly, all such modifications are intended to be included within the scope of the present inventions. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the preferred and other exemplary embodiments without departing from scope of the present disclosure or from the spirit of the appended claims.
This application is a continuation of U.S. patent application Ser. No. 17/307,847, filed May 4, 2021, and titled IN-MOLDED HELMET CHINBAR, which is a continuation of U.S. patent application Ser. No. 15/147,750, filed May 5, 2016, and titled IN-MOLDED HELMET CHINBAR, both of which are incorporated herein in their entirety by reference thereto.
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