Protective Helmets, Protective Helmet Components and Methods for Manufacturing Protective Helmets, Including Protective Helmets Having an Enlargeable Bell Opening

Abstract

The present invention relates to protective helmets. Embodiments of the invention have been primarily developed to provide protective helmets, protective helmet components and methods for manufacturing protective helmets, including protective helmets having an enlargeable bell opening. For example, embodiments are described by reference to two-part helmets having a hinged connection which permits bell opening enlargement to enable insertion or removal of a human head. One embodiment provides a manufacturing method whereby a protective helmet is formed as a single piece, and then cut into shell portions to which interlocking edge members is subsequently applied, thereby to facilitate reconnection of the shells along an interlocking edge.

Description

FIELD OF THE INVENTION

The present invention relates to protective helmets. Embodiments of the invention have been primarily developed to provide protective helmets, protective helmet components and methods for manufacturing protective helmets, including protective helmets having an enlargeable bell opening. For example, embodiments are described by reference to two-part helmets having a hinged connection which permits bell opening enlargement to enable insertion or removal of a human head.

BACKGROUND

Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of common general knowledge in the field.

PCT Publication WO 2012/058712 and WO 2007/059575 both disclose examples of protective helmets having enlargeable bell openings. More specifically, those publications focus on hinged rear-opening protective helmets, where a front and rear shell rotate relative to one another to provide an open configuration in which the helmet is able to be applied or removed, and a closed configuration in which it is secured on a wearer's head. This the act of opening enlarges the bell opening of the helmet, enabling convenient insertion of the head. In some embodiments the bell opening is sized thereby to prevent removal of the helmet when in the closed configuration (referred to as a restricted bell opening helmet). Other forms of enlargeable (and/or restricted) bell opening helmets are also possible, for example where two shells are connected by an arrangement other than a dorsal hinge.

There are various technical challenges associated with constructing helmets having enlargeable bell openings. For example:

Technical challenges arise during manufacture of two-part helmets, particularly where there is a desire to use composite shell materials (as opposed to injection moulding and the like). In particular, it is difficult to precisely size-match separately formed front and rear shells.There are inherent challenges involved in designing a locking mechanism for forms of enlargeable (and/or restricted) bell opening helmets, and other forms of helmets having multiple shell portions. In particular, the strength of a locking mechanism should be considerable, for instance as is necessary to satisfy various helmet safety standards internationally.There are inherent challenges involved in designing a hinge mechanism for forms of enlargeable (and/or restricted) bell opening helmets, and other forms of helmets having multiple shell portions. This is most prevalent where the helmet is being used for protective purposes, and there is a need to manage risks associated with a hinge presenting a potential point of failure.

It is an object of the present invention to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative.

SUMMARY

One embodiment provides a method of manufacturing a helmet, the method including:

forming a primary helmet shell, the helmet shell having a bell opening defined by a bell opening edge;

applying a cutting process to the primary helmet shell thereby to define a first shell component and a second shell component, such each of the first and second shell components include respective regions of the bell opening edge;

for at least one of the first and second shell components, mounting at least one interlocking edge member to an edge of the shell component, being an edge defined by the cutting process; and

constructing a helmet including the at least one of the first and second shell components to which the at least one interlocking edge member is mounted, wherein the constructed helmet is movable between: (i) a closed configuration in which the at least one interlocking edge member is engaged with a complementary opposing interlocking edge; and (ii) an open configuration.

One embodiment provides a method of manufacturing a helmet, including:

for each of the for at least one of the first and second shell components, mounting at least one interlocking edge member to an edge of the shell component, being an edge defined by the cutting process; and

constructing a helmet including the first and second shell components, wherein the constructed helmet is movable between: (i) a closed configuration in which the respective at least one interlocking edge members of the first and second shell components are complementarily engaged; and (ii) an open configuration.

One embodiment provides a method of manufacturing a helmet, including:

for each of the for at least one of the first and second shell components, mounting a pair of interlocking edge member to an edge of the shell component, being an edge defined by the cutting process; and

constructing a helmet including the first and second shell components, wherein the constructed helmet is movable between: (i) a closed configuration in which the pair of interlocking edge members of the first shell component are complementarily engaged with the pair of interlocking edge members of the second shell component; and (ii) an open configuration.

One embodiment provides a method of manufacturing a helmet, the method including:

forming a primary helmet shell, the helmet shell having a bell opening defined by a bell opening edge;

applying a cutting process to the primary helmet shell thereby to define a first shell component and a second shell component;

for at least one of the first and second shell components, mounting at least one interlocking edge member to an edge of the shell component, being an edge defined by the cutting process; and

constructing a helmet including the at least one of the first and second shell components to which the at least one interlocking edge member is mounted.

Embodiments also include helmets formed by any method described herein.

One embodiment provides a latch assembly for an expandable bell opening helmet, the latch assembly including:

a first set of latch assembly components which are configured to be mounted to a first shell component of the expandable bell opening helmet; and

a second set of latch assembly components which are configured to be mounted to a second shell component of the expandable bell opening helmet;

wherein:

the first shell is movable with respect to the second shell thereby to define an open and closed configuration for the helmet, wherein: in the open configuration the bell opening is expanded; and in the closed configuration the first set of latch assembly components interface with the second set of latch assembly components thereby to lock the helmet in the closed configuration; and

the first set of latch assembly components includes: (i) a trappable member receiving region, wherein the trappable member receiving region includes tapered edges configured to guide a trappable member into the trappable member receiving region; and (ii) a biased capture mechanism, wherein the biased capture mechanism is configured to prevent removal of the trappable member in the trappable member receiving region under influence of spring loading;

the second set of latch assembly components includes a first plate member that provides the trappable member.

One embodiment provides a latch assembly for an expandable bell opening helmet, wherein:

the first set of latch assembly components includes a first non-locking capture mechanism, wherein the first non-locking capture mechanism is configured to be mounted to the first helmet shell component at a location spaced apart from locking latch assembly components;

the second set of latch assembly components includes a second non-locking capture mechanism; which is configured to engage with the first non-locking capture mechanism, wherein the second non-locking capture mechanism is configured to be mounted to the first helmet shell component at a location spaced apart from locking latch assembly components;

in use, the first and second non-locking latch assembly components engage upon closure of the helmet thereby to restrict relative movement of the helmet shell components along at least a first axis and a second axis, the first axis being substantially parallel to a shell edge and the second axis being substantially normal to a shell surface.

One embodiment provides a latch assembly for an expandable bell opening helmet, the latch assembly including:

a first set of latch assembly components which are configured to be mounted to a first shell component of the expandable bell opening helmet; and

a second set of latch assembly components which are configured to be mounted to a second shell component of the expandable bell opening helmet;

wherein:

the first shell is movable with respect to the second shell thereby to define an open and closed configuration for the helmet, wherein: in the open configuration the bell opening is expanded; and in the closed configuration the first set of latch assembly components interface with the second set of latch assembly components thereby to lock the helmet in the closed configuration; and

the first set of latch assembly components includes first lockable components;

the second set of latch assembly components includes second lockable components configured to lock to the first lockable components upon closure of the helmet;

the first set of latch assembly components includes a first non-locking capture mechanism, wherein the first non-locking capture mechanism is configured to be mounted to the first helmet shell component at a location spaced apart from the first lockable components;

the second set of latch assembly components includes a second non-locking capture mechanism; which is configured to engage with the first non-locking capture mechanism, wherein the second non-locking capture mechanism is configured to be mounted to the first helmet shell component at a location spaced apart from the second locking components;

in use, the first and second non-locking latch assembly components engage upon closure of the helmet thereby to restrict relative movement of the helmet shell components along at least a first axis and a second axis, the first axis being substantially parallel to a shell edge and the second axis being substantially normal to a shell surface.

Embodiments also include helmets including latch assemblies as described herein.

One embodiment provides a hinge assembly for an expandable bell opening helmet, the hinge assembly including:

a first set of hinge assembly components which are configured to be mounted to a first shell component of the expandable bell opening helmet; and

a second set of hinge assembly components which are configured to be mounted to a second shell component of the expandable bell opening helmet, wherein the first set of hinge components is configured to engage with the second set of hinge components thereby to define a hinge that rotates about a hinge axis;

wherein:

the first shell is movable with respect to the second shell thereby to define an open and closed configuration for the helmet; and

the first and second sets of hinge assembly components are mounted to the respective shell components to provide a hinged connection and enable the movement of the first shell with respect to the second shell about the hinge axis.

Other embodiments include helmets having hinge assemblies as herein described.

One embodiment provides an expandable bell opening helmet having at least one interlocking edge component formed independently of a helmet shell component to which it is fixedly mounted, the helmet movable between: (i) a closed configuration in which the at least one interlocking edge member is engaged with a complementary opposing interlocking edge; and (ii) an open configuration.

One embodiment provides a composite helmet formed from two shells, wherein the shells engage along respective interlocking edges.

One embodiment provides a composite helmet wherein at least one of the shells provides its respective interlocking edge by way of mounting of an interlocking edge component to the shell.

Reference throughout this specification to “one embodiment”, “some embodiments” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment”, “in some embodiments” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments.

As used herein, unless otherwise specified the use of the ordinal adjectives “first”, “second”, “third”, etc., to describe a common object, merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking, or in any other manner.

In the claims below and the description herein, any one of the terms comprising, comprised of or which comprises is an open term that means including at least the elements/features that follow, but not excluding others. Thus, the term comprising, when used in the claims, should not be interpreted as being limitative to the means or elements or steps listed thereafter. For example, the scope of the expression a device comprising A and B should not be limited to devices consisting only of elements A and B. Any one of the terms including or which includes or that includes as used herein is also an open term that also means including at least the elements/features that follow the term, but not excluding others. Thus, including is synonymous with and means comprising.

As used herein, the term “exemplary” is used in the sense of providing examples, as opposed to indicating quality. That is, an “exemplary embodiment” is an embodiment provided as an example, as opposed to necessarily being an embodiment of exemplary quality.

The disclosures of PCT Publications WO 2012/058712 and WO 2007/059575 are incorporated by cross reference in their entireties.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

FIG. 1 provides a side view of a helmet according to one embodiment.

FIG. 2A to FIG. 2D schematically illustrate a manufacturing process for an interlocking edge arrangement for a helmet such as that of FIG. 1.

FIG. 3A and FIG. 3B provide views of a helmet latch arrangement according to one embodiment, which is in some embodiments used for the helmet of FIG. 1.

FIG. 4A and FIG. 4B provide further views of the helmet latch arrangement.

FIG. 5 provides a further view of the helmet latch arrangement, shown in conjunction with a secondary locator arrangement.

FIG. 6 shows the helmet of FIG. 1 with the locator arrangement of FIG. 5.

FIG. 7 shows a more detailed view of a region of the FIG. 5, focussed on the locator arrangement.

FIG. 8A to FIG. 8I illustrate operation of a helmet latch arrangement according to one embodiment.

FIG. 9 illustrates a helmet dorsal hinge arrangement according to one embodiment, which is in some embodiments used for the helmet of FIG. 1.

FIG. 10 provides a further view of the helmet dorsal hinge arrangement.

FIG. 11 provides a further view of the helmet dorsal hinge arrangement.

FIG. 12 provides a further view of the helmet dorsal hinge arrangement.

FIG. 13 provides a further view of the helmet dorsal hinge arrangement, shown in cross-section with the helmet of FIG. 1.

FIG. 14 provides a further view of the helmet dorsal hinge arrangement, shown in cross section.

FIG. 15 provides a view of a further exemplary helmet dorsal hinge arrangement, shown in cross section.

FIG. 16A and 16B provide a further views of the hinge arrangement of FIG. 15.

FIG. 17A and 17B illustrate operation of the hinge arrangement of FIG. 15.

FIG. 18 provides a further view of the hinge arrangement of FIG. 15.

FIG. 19A and FIG. 19B illustrate a visor connection arrangement according to one embodiment.

FIG. 20A and FIG. 20B illustrate a disc component of the visor connection arrangement of FIG. 19A and FIG. 19B.

FIG. 21A to FIG. 21C provide further views of the visor connection arrangement.

FIG. 22 illustrates the visor connection arrangement in cross-section.

DETAILED DESCRIPTION

The present invention relates to protective helmets, and methods for manufacturing protective helmets. Embodiments described herein are particularly relevant to protective helmets having enlargeable bell openings, for example rear opening helmets.

Context

As noted, embodiments described herein are particularly relevant to protective helmets having enlargeable bell openings, for example rear opening helmets. Examples of helmets are disclosed in PCT Publication WO 2012/058712 and WO 2007/059575. In overview, such helmets include two (or, in some embodiments, more) shell portions which are movable relative to one another thereby to enlarge the helmet's bell opening (the opening into which a user's head is inserted to apply the helmet).

A significant subset of enlargeable bell opening helmets is “restricted bell opening helmets”. Such helmets are sized such that the bell opening is circumferentially smaller than the user's lower head (for example at the height of the chin). This prevents the helmet from being applied or removed when shell portions collectively defining the bell opening are in a closed configuration. Those shell portions must be moved relative to one another, into an open configuration, to permit a user to apply or remove the helmet. In this regard, the use of a restricted bell opening design is optionally implemented as an alternative to conventional chin strap designs (where the bell opening is of a fixed size that permits application and removal of the helmet, with a chin strap used to prevent premature or other unwanted removals of the helmet).

It should be appreciated that, where the present disclosure deals with relative sizes of a user's head and a helmet, it is to be interpreted that the helmet has an intended head size range, and the user in question has a head size falling within that range. That is, the disclosure herein describes example helmets that are sized for a range of user head sizes into which example user's heads described herein fall. Accordingly, where a “helmet is sized such that the bell opening is circumferentially smaller than the user's lower head”, that refers to a user having a head size in a range for which the helmet is specifically configured.

In some examples considered below, restricted bell opening helmets are defined by cutting a full helmet shell into two portions, for example a front and rear portion. This results in splitting of an edge that defines the bell opening, such that enlarging the bell opening includes moving the bell opening portions of the front and rear shell relative to one another. The cut line that separates the shells is defined such that, when in the open configuration, the bell opening can be considered as either: (i) an opening defined by the closed-configuration bell opening edges and space defined there between; or (ii) an opening defined by the closed-configuration bell opening edges and edges of opposed shell edges that abut/interconnect when the helmet is in the closed configuration. The cut line between the shell potions is defined such that, for a helmet designed for a head in a size range X-Y, a head in the size X-Y:

Is not able to be inserted into the helmet in a closed configuration;Is not able to be removed from the helmet in the closed configuration (due to bell opening sizing relative to head dimensions at approximately chin level); andIs able to be progressed into the front shell in a generally forward manner when the head is open due to an adequate opening being defined by the front shell edge along which interlocking occurs.

The examples disclosed in PCT Publications WO 2012/058712 and WO 2007/059575 show a form of enlargeable bell opening helmets: rear opening helmets. These include a front shell and a rear shell, with the rear shell being movable with respect to the front shell to enlarge the bell opening (and hence permit helmet application and removal). More particularly, the helmets of those publications make use of a dorsal hinge connection, which permits relative rotation of the front and rear shells. Side fasteners (for example latch arrangements) enable the locking of the helmet in the closed configuration.

Various embodiments are described below by reference to a rear-opening helmet similar to that of PCT Publications WO 2012/058712 and WO 2007/059575, in the sense of there being utilisation of a dorsal hinge and side fasteners. However, it should be appreciated that the various aspects of technologies described (for example by reference to helmet manufacturing methods, latch arrangements and visor arrangements) are by no means limited to that specific form of enlargeable bell opening helmet, and are applicable to a wide range of other forms of enlargeable bell opening helmets, and in some cases to protective helmets more generally.

By way of example, other possible configurations include:

Hinges other than dorsal hinges—for example side hinges.Arrangements in which two shell components collectively defining the bell opening are configured to be slidable relative to one-another. For example, the rear shell, or a rear shell region, is rearwardly slidable along a defined track to define the open configuration.Arrangements in which two shell components collectively defining the bell opening are detachable and re-attachable to respectively open and close the helmet. In some cases upon detachment, a secondary connection arrangement (for example a resiliently biased tether, such as an elastic connection) biases the detached shells towards the closed configuration.Any helmet where a rear portion partially defining a bell opening is movable thereby to enable insertion of a head into a restricted bell opening helmet.Any helmet where a shell portion containing chin cup component (for example an adjustable and/or resiliently biased chin cup component as disclosed in 2007/059575) is movable thereby to enable insertion of a head into a restricted bell opening helmet.

Various other configurations are also possible.

Exemplary Helmet

FIG. 100 illustrates a helmet 100 according to one embodiment. Various aspects of helmet technology, which also form embodiments of inventions disclosed herein, are illustrated in conjunction with the helmet of FIG. 1.

Helmet 100 is defined by a front shell 101 and a rear shell 102, which are separated along a separation line 103. The helmet is illustrated in side view, with a visor 105 at the front, and a restricted bell opening at the bottom. As discussed above, due to the restricted bell opening, the helmet is sized such that a wearer can only apply or remove the helmet when it is in an open configuration (where the bell opening is enlarged due to relative movement of shells 101 and 102).

The shells include respective interlocking edge regions. In particular, at least a portion of the edge of each shell at the separation line includes male or female regions, which interlockingly engage with complementary female or male regions on the opposing shell edge upon closure. Various interlocking edge designs and configurations are used in embodiments, and a range of examples are illustrated in WO 2007/059575. In the illustrated, the interlocking edges are present along side regions of the helmet. More particularly, on each side of the helmet they extend substantially from the hinge assembly to a latch assembly (which is in FIG. 1 concealed by latch assembly covers 110 and 111).

In this embodiment, interlocking edge components 108 and 109 are illustrated. These components are formed from plastics materials (preferably with resilient properties), and connected to the helmet shells during a manufacture process discussed further below. However, in some embodiments either or both of the interlocking edge components may be integrally formed with the helmet shell.

In the illustrated embodiment, both the front and rear shells are constructed from composite materials (for example carbon fibre), using a construction technique discussed further below by which the shells are initially defined by a single helmet, which is subsequently cut to define the two separate shells. However, in other embodiments alternate materials are used, and alternate construction techniques used. For instance, in some embodiments either or both shells are formed from ABS (Acrylonitrile Butadiene Styrene).

Shell 101 is hingedly connected to shell 102 by a dorsal hinge assembly at region 104 (described in more detail further below). This allows shells 101 and 102 to rotate relative to one another about the axis of the hinge of the hinge assembly, generally along a path illustrated by arrow 106.

Upon closure of the helmet, interlocking edge components 108 and 109 complementarily engage, and the latch assembly (concealed by covers 110 and 111) on each side of the helmet automatically locks the helmet shells securely together (by way of a spring-loaded arrangement) as discussed further below. To re-open the helmet, a user manipulates buttons 112 provided for each of the side latch assemblies thereby to release the latch assemblies, and allow outward relative rotation of the shells.

An adjustable chin cup component is provided within the helmet at region 120. This is adjusted based on a particular user's size, thereby to cup the wearer's chin when the helmet is worn, and allow limited some resiliently restrained motion of the chin relative to the hard shell at region 120. The chin cup is not to be confused with a chin strap; a chin cup is a component that is configured to content a wearer's chin region at locations at each side or, and preferably both above and below, a chin-point extremity of the wearer's chin. A chin strap, on the other hand, is a component that is configured to be located below a wearer's chin.

Manufacturing Method Enabling Separable Interlocking Edge Components

FIG. 2A to FIG. 2D schematically illustrate a manufacturing process for an interlocking edge arrangement for a helmet such as helmet 100 of FIG. 1.

Known two-part helmet configurations make use of interlocking edges that are integrally formed from the helmet shells. This typically necessitates initial construction of two individual shells, which can be problematic due to issues such as inconsistent shrinkage of the shells. It also creates challenges in using a full composite helmet, as the composite materials are not suitable for formation of integral interlocking edges (which may favour using a helmet that has a composite front shell and an ABS rear shell).

Embodiments of the present technology include helmets and manufacturing techniques that make use of interlocking edge components which are manufactured independently of helmet shells, and mounted to helmet shells during the manufacture process. Some embodiments include a manufacturing process that includes:

Forming a primary helmet shell, the helmet shell having a bell opening defined by a bell opening edge;Applying a cutting process to the primary helmet shell thereby to define a first shell component and a second shell component, such each of the first and second shell components include respective regions of the bell opening edge;For at least one of the first and second shell components, mounting at least one interlocking edge member to an edge of the shell component, being an edge defined by the cutting process; andConstructing a helmet including the at least one of the first and second shell components to which the at least one interlocking edge member is mounted, wherein the constructed helmet is movable between: (i) a closed configuration in which the at least one interlocking edge member is engaged with a complementary opposing interlocking edge; and (ii) an open configuration.

Preferably the method includes, for each of the for at least one of the first and second shell components, mounting at least one interlocking edge member to an edge of the shell component, being an edge defined by the cutting process. This then involves constructing a helmet including the first and second shell components, wherein the constructed helmet is movable between: (i) a closed configuration in which the respective at least one interlocking edge members of the first and second shell components are complementarily engaged; and (ii) an open configuration.

There are various design options available for interlocking edge configurations. For example, an one interlocking edge member may be mounted to either or both shells, and on either shell there may be a single interlocking edge member or multiple interlocking edge members (for example with the multiple members defining a segmented interlocking edge).

In a preferred embodiment, the method includes, for each of the first and second shell components, mounting a pair of interlocking edge member to an edge of the shell component. This is the case in FIG. 1, where a pair of interlocking edge members 108 are mounted to shell component 101 (extending substantially from the hinge assembly to a latch assembly), and a pair of interlocking edge members 109 are mounted to shell component 101 (extending substantially from the hinge assembly to a latch assembly). That is, there is a member 108 on each side of the helmet, and a member 109 on each side of the helmet.

FIG. 2A illustrates, in cross section, a region of a composite helmet shell that is initially formed. This includes a recessed region 201, which extends along a circumference of the shell. The width and depth of the recessed region varies along its length, depending on components that are to be mounted. For example, FIG. 13 shows a portion of a recessed region which is sized and shaped to enable concealed mounting of a hinge assembly.

The cutting process is applied to helmet shell 200, thereby to define helmet shell components 210 and 211 (which may correspond to shell components 101 and 102 of FIG. 1). Here, the cutting process includes removing one or more shell regions defined between an edge of the first shell defined by the current process and an edge of the second shell defined by the cutting process. One of these is shown as region 212. These regions are have a width dimension substantially corresponding to a width dimension between the first and second shell components when the helmet is in the closed configuration, as best shown in FIG. 2D. In essence, the removed regions account for the inter-shell pace occupied by the interlocking edge components.

As shown in FIG. 2C, interlocking edge components 220 and 221 are mounted to edges of shell components 201 and 211 (being edges defined during the cutting process). The interlocking edge components are elongate, and mounted to extend along those helmet shell edges for a portion (preferably a substantial portion) of the edges that is not occupied by hinge components, latch components, and so on.

Interlocking edge components 102 and 211 are preferably formed of plastics (for example via an injection moulding process, 3D printing process, or the like), and are in some embodiments formed of a plastics material having resilient properties thereby to allow limited resilient movement between the shells of the closed helmet.

At least one of the interlocking edge members includes a male region 222 that interlocks with a complementary female region 223 of the other interlocking edge member. In some embodiments one interlocking edge member is wholly male and the other female, but in other embodiments they each include both male and female regions. It will be appreciated that a wide range of interlocking edge designs may be achieved using construction techniques such as injection moulding and/or 3D printing. FIG. 2D shows mutual engagement of the male and female portions, which occurs upon closure of a fully constructed helmet.

The interlocking edge members are in the illustrated embodiment sandwich mounted around each helmet shell along an edge defined by recessed region 201. This may be achieved by way any one or more of: adhesives, heat, mounting members (such as rivets or screws) and so on. In some cases apertures are formed through a shell adjacent the edge to assist in such mounting.

Exemplary Latch Arrangement

FIG. 3A to FIG. 7 illustrate an exemplary latch arrangement for the helmet of FIG. 1. In overview, some embodiments include latch assembly for an expandable bell opening helmet, such as the helmet of FIG. 1 (which includes two such latch assemblies; one on each side).

Referring to FIG. 4A, a latch assembly 400 a first set of latch assembly components 401 which are configured to be mounted to shell component 101, and a second set of latch assembly components 402 which are configured to be mounted to a second shell component of the expandable bell opening helmet.

The first set of latch assembly components 401 includes a trappable member receiving region 410 (partially concealed in FIG. 4A). The trappable member receiving region includes tapered edges configured to guide a trappable member 411 (provided on a first plate member 412, mounted to the helmet shell by mounting components 421) into the trappable member receiving region. That is, upon closure of the helmet, those tapered edges assist in progressively guiding the trappable member into the trappable member receiving region to a point where it is configured to be trapped. The trapping is effected by way of a spring loaded capture mechanism, the spring loaded capture mechanism being is configured to prevent removal of the trappable member in the trappable member receiving region under influence of spring loading.

The spring loaded capture mechanism is configured to move against the direction of spring loading upon engagement with the trappable member as that trappable member is progressed towards the trappable member receiving region, thereby enabling automated insertion and capture of the trappable member in the trappable member receiving region. In this embodiment, such a functionality is achieved by way of a sloped edge 414.

The trappable member receiving region is defined by a second plate member 415 that is configured to be mounted to the first helmet shell component (see mounting components 420 of FIG. 4B). The spring loaded capture mechanism is rotationally mounted to the second plate member by an axel mount 422.

The spring loaded capture mechanism includes a button component 425 which is configured to be manually manipulated thereby to enable movement of the spring loaded capture mechanism against the direction of spring loading, and hence enable removal of the trappable member from the trappable member receiving region.

Upon engagement, the first plate member 412 and the second plate member 415 correctively sandwich a guide plate member 425 of the spring loaded capture mechanism.

The trappable member includes a region of first radius that extends from first plate 412, which is captured in the trappable member receiving region 410, and a region of second radius which extends from the region of first radius, wherein the region of second radius and the guide plate collectively sandwich second plate member 415.

FIG. 8A to FIG. 8I illustrate operation of a latch arrangement having corresponding characteristics to that described above. Corresponding reference numbers are used in FIG. 8A to FIG. 4A and FIG. 4B. However FIG. 8A is shown without a component corresponding to button 425 for the sake of clarity, although it will be appreciated how such a button is able to be mounted at or proximal region 430.

FIG. 8A illustrates the direction of rotation of the spring loaded capture mechanism for the purpose of unlocking/opening. As shown in FIG. 8B, this rotation brings the guide plate away from the trappable member receiving region, thereby allowing removal of the trappable member as shown in FIG. 8C. The spring loaded capture mechanism then returns to its spring loaded bias position as shown in FIG. 8D and FIG. 8E.

FIG. 8F illustrates the direction of approach of the trappable member upon closure of the helmet (by relative rotation of the shells). This pushes against sloped surface 414, thereby to act against the spring bias, and allow capture of the trappable member in the trappable member receiving region upon return of the spring loaded capture component (see FIG. 8H).

FIG. 8I provides a rear perspective view showing an optional location for a spring component 460 which provides spring loading for the spring loaded capture component.

Referring to FIG. 5, in some embodiments (such as that of FIG. 1), latch assembly 400 includes a non-locking latch component 470. In overview, this is mounted at a location spaced apart from locking components 401 and 402, for example as shown in FIG. 6 and FIG. 7. The locking components are configured primarily to provide locking functionality. The non-locking components are configured to provide robust inter-shell locating for helmet structural integrity upon closure. Latch component 470 includes a non-locking capture mechanism 472, including a prong 474, and a second non-locking capture mechanism 471; which is configured to engage with non-locking capture mechanism 472, including a prong capturing loop 473. The prong preferably has a tapered leading end, to assist in accurate insertion into the prong capturing loop.

In use, non-locking latch assembly components 471 and 472 engage upon closure of the helmet thereby to restrict relative movement of the helmet shell components along at least a first axis and a second axis, the first axis being substantially parallel to a shell edge and the second axis being substantially normal to a shell surface.

Exemplary Dorsal Hinge Assembly

FIG. 9 illustrates dorsal hinge assembly 900 according to one embodiment for the helmet of FIG. 1. Further views are shown in FIG. 10 to FIG. 14. Notably, FIG. 13 provides a cross-section of the dorsal hinge arrangement mounted to the helmet of FIG. 1.

Assembly 900 includes a first set of hinge assembly components 901 which are configured to be mounted to a shell component 101. More specifically, components 901 include an injection moulded hinge half 910. This includes formations 912 that are configured to receive threaded screws for securing to hinge half 910 the helmet shell. Apertures 913 provides access to selectively insert or remove screws, which as discussed below enables detachment of hinge half 910 thereby to allow a safety release function, as discussed further below.

A second set of hinge assembly components 902 which are configured to be mounted to shell component 102. These include an injection moulded hinge half 920, which is secured through the shell component using mounting formations 921. These are not externally accessible, and hinge half 920 is not intended to be removed as part of intended helmet operation.

Hinge half 901 is configured to engage with hinge half 920 thereby to define a hinge that rotates about a hinge axis defined by a hinge pin 930. The relative positioning of axial apertures defined through hinge halves 910 and 920 allows a substantially smooth top surface transition between the hinge halves. As shown in FIG. 13, this is mounted in a recess such that the hinge assembly sits substantially flush with the helmet surface, adopting a similar overall curved configuration.

Hinge halves 910 and 920 each include a plurality of parallel ribs, with a hinge pin receiving aperture being formed axially through those ribs. The ribs inter-engage in a multi-layer sandwich configuration when the hinge assembly is formed, which is beneficial in terms of providing rigidity to the hinge. Furthermore, the ribs are shaped such that upon detachment of hinge half 910 from shell component 101, hinge half 910 is able to be laterally separated from the hinge pin, thus enabling separation of the shell components from one another without removing the hinge pin from hinge half 920.

FIG. 16A to FIG. 18 provide views of an alternate hinge assembly having similar features. Corresponding reference numerals are provided in FIG. 16A for guidance. FIG. 16A additionally illustrates an elastomer spring 980 configured to resiliently bias the hinge assembly out of a defined closed helmet hinge assembly position. This means that: (i) additional force is required to close the helmet, reducing the likelihood of accidental closure; and (ii) upon manipulating the latch release buttons, the helmet automatically springs open.

Conclusions and Interpretation

It should be appreciated that in the above description of exemplary embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, FIG., or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of this invention.

Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those skilled in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.

In the description provided herein, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.

Thus, while there has been described what are believed to be the preferred embodiments of the invention, those skilled in the art will recognize that other and further modifications may be made thereto without departing from the spirit of the invention, and it is intended to claim all such changes and modifications as falling within the scope of the invention. For example, any formulas given above are merely representative of procedures that may be used. Functionality may be added or deleted from the block diagrams and operations may be interchanged among functional blocks. Steps may be added or deleted to methods described within the scope of the present invention.

Claims

1. (canceled)

2. (canceled)

3. (canceled)

4. (canceled)

5. (canceled)

6. (canceled)

7. (canceled)

8. (canceled)

9. (canceled)

10. (canceled)

11. A method of manufacturing a helmet, the method including: forming a primary helmet shell, the helmet shell having a bell opening defined by a bell opening edge;applying a cutting process to the primary helmet shell thereby to define a first shell component and a second shell component;for at least one of the first and second shell components, mounting at least one interlocking edge member to an edge of the shell component, being an edge defined by the cutting process; andconstructing a helmet including the at least one of the first and second shell components to which the at least one interlocking edge member is mounted.

12. A method according to claim 11 including: for each of the for at least one of the first and second shell components, mounting at least one interlocking edge member to an edge of the shell component, being an edge defined by the cutting process; andconstructing a helmet including the first and second shell components.

13. A method according to claim 12 including: for each of the for at least one of the first and second shell components, mounting a pair of interlocking edge member to an edge of the shell component, being an edge defined by the cutting process.

14. (canceled)

15. A method according to claim 12 wherein the cutting process includes removing one or more shell regions defined between an edge of the first shell defined by the current process and an edge of the second shell defined by the cutting process.

16. A method according to claim 15 wherein at least one of the removed shell regions has a width dimension substantially corresponding to a width dimension between the first and second shell components when the helmet is in the closed configuration.

17. A method according to claim 12 wherein the at least one interlocking edge member mounted to the first shell component includes a male region that interlocks with a complementary female region of the at least one interlocking edge member mounted to the second shell component when the helmet is in the closed configuration.

18. A method according to claim 12 wherein the helmet includes a hinge assembly that is configured to enable relative rotation of the first shell component relative to the second shell component, thereby to enable enlargement of the bell opening.

19. A method according to claimer 18 wherein the helmet includes at least one latch assembly that enable securing of the helmet in the closed configuration.

20. A method according to claimer 19 wherein the at least one interlocking edge member is mounted to the first shell component along an edge region defined by the cutting process intermediate the hinge assembly and the at least one latch assembly.

21. A method according to claim 11 wherein the at least one interlocking edge component is formed of resilient material.

22. A helmet formed by a method according to claim 11.

23. An expandable bell opening helmet having at least one interlocking edge component formed independently of a helmet shell component to which it is fixedly mounted, the helmet movable between: (i) a closed configuration in which the at least one interlocking edge member is engaged with a complementary opposing interlocking edge; and (ii) an open configuration.

24. (canceled)

25. (canceled)

26. A latch assembly for an expandable bell opening helmet, the latch assembly including: a first set of latch assembly components which are configured to be mounted to a first shell component of the expandable bell opening helmet; anda second set of latch assembly components which are configured to be mounted to a second shell component of the expandable bell opening helmet;wherein: the first shell is movable with respect to the second shell thereby to define an open and closed configuration for the helmet, wherein: in the open configuration the bell opening is expanded; and in the closed configuration the first set of latch assembly components interface with the second set of latch assembly components thereby to lock the helmet in the closed configuration; andthe first set of latch assembly components includes: (i) a trappable member receiving region, wherein the trappable member receiving region includes tapered edges configured to guide a trappable member into the trappable member receiving region; and (ii) a biased capture mechanism, wherein the biased capture mechanism is configured to prevent removal of the trappable member in the trappable member receiving region under influence of spring loading;the second set of latch assembly components includes a first plate member that provides the trappable member.

27. (canceled)

28. (canceled)

29. (canceled)

30. (canceled)

31. (canceled)

32. (canceled)

33. (canceled)

34. (canceled)

35. (canceled)

36. (canceled)

37. A helmet including a latch assembly according to claim 26.

38. A hinge assembly for an expandable bell opening helmet, the hinge assembly including: a first set of hinge assembly components which are configured to be mounted to a first shell component of the expandable bell opening helmet; anda second set of hinge assembly components which are configured to be mounted to a second shell component of the expandable bell opening helmet, wherein the first set of hinge components is configured to engage with the second set of hinge components thereby to define a hinge that rotates about a hinge axis;wherein: the first shell is movable with respect to the second shell thereby to define an open and closed configuration for the helmet; andthe first and second sets of hinge assembly components are mounted to the respective shell components to provide a hinged connection and enable the movement of the first shell with respect to the second shell about the hinge axis.

39. (canceled)

40. (canceled)

41. (canceled)

42. (canceled)

43. A helmet including a hinge assembly according to claim 38.

44. A method according to claim 11 wherein the cutting process is applied such that each of the first and second shell components include respective regions of the bell opening edge; and wherein the constructed helmet is movable between: (i) a closed configuration in which the at least one interlocking edge member is engaged with a complementary opposing interlocking edge; and (ii) an open configuration.

45. A method according to claim 12 wherein the constructed helmet is movable between: (i) a closed configuration in which the respective at least one interlocking edge members of the first and second shell components are complementarily engaged; and (ii) an open configuration.

46. A method according to claim 13 including constructing a helmet including the first and second shell components, wherein the constructed helmet is movable between: (i) a closed configuration in which the pair of interlocking edge members of the first shell component are complementarily engaged with the pair of interlocking edge members of the second shell component and (ii) an open configuration.