Patent Application
20230371640
N/A.
Helmets are generally worn to provide a buffer between a user's head and an object that comes into contact with the helmet. While helmets are used during various activities, such as during construction, mining, etc., a large proportion of manufactured helmets are used for sporting activities. For example, bicycle helmets are worn by cyclists, which when worn appropriately under certain circumstances can help to provide a buffer in the event of a fall or crash. Generally, such helmets are secured in place by a strap system consisting of straps attached to left and right sides of the helmet, respectively, and each including mating latch features that can be secured together under the wearer's chin. In the event of a fall or crash, the localized attachment points between the straps and the helmet can experience significant retention loads. It would be desirable to have systems and methods for helmet constructions that allow for improved strap retention load distribution.
Some embodiments of the disclosure provide a helmet. The helmet can include a body defining a front end, a rear end opposite the front end, a first lateral end and a second lateral end opposite the first lateral end. The body further defines one or more vents extending therethrough. The helmet also includes a structure at least partially embedded in the body and encircling at least one vent of the one or more vents, and a strap hanger coupled to the structure.
In some embodiments, the structure is a cage. In some embodiments, the cage comprises multiple longitudinal beams that extend between the rear end and the front end. The cage further comprises a transverse beam that extends between the first lateral end and the second lateral end, where the transverse beam is coupled to one or more of the multiple longitudinal beams. The one or more vents are situated between different pairs of adjacent longitudinal beams of the multiple longitudinal beams. In some embodiments, the body fully encapsulates the multiple longitudinal beams of the cage and partially encapsulates the transverse beam. Additionally, in some embodiments, the transverse beam extends through at least one of the one or more vents.
In some embodiments, the structure is a butterfly. Further, in some embodiments, the butterfly comprises a front butterfly located within the body proximate the front end and a rear butterfly located within the body proximate the rear end.
In some embodiments, the strap hanger comprises a clip, a strap receiver configured to receive a strap therethrough, and webbing that connects the clip to the strap receiver. In some embodiments, the clip is configured to snap onto the structure via a press-fit engagement. Furthermore, in some embodiments, the strap hanger is partially encapsulated by the body, and the strap receiver remains exposed outside of the body to receive the strap therethough after the strap hanger is partially encapsulated by the body. In some embodiments, the clip, the strap, and the webbing are integrally formed.
In some embodiments, the strap hanger includes a first front strap hanger located near the front end along the first lateral end, a second front strap hanger located near the front end along the second lateral end, a first rear strap hanger located near the rear end along the first lateral end, and a second rear strap hanger located near the rear end along the second lateral end. In some embodiments, the first front strap hanger and the first rear strap hanger are identical. Additionally, in some embodiments, the strap hanger is made of plastic.
Some embodiments provide a helmet that can include a body, a cage, and a strap hanger. The body defines one or more vents extending therethrough. The cage is at least partially embedded in the body and encircles at least one vent of the one or more vents. The strap hanger is coupled to the cage.
In some embodiments, the strap hanger comprises a clip, a strap receiver configured to receive a strap therethrough, and webbing that connects the clip to the strap receiver. In some embodiments, the clip snaps onto the cage via a press-fit engagement. In some embodiments, the clip includes two clips that each snap onto the cage. Additionally, in some embodiments, the webbing includes two wings that extend outward from the strap receiver.
In some embodiments, the cage defines a front end, a rear end opposite the front end, a first lateral end and a second lateral end opposite the first lateral end. The cage also comprises multiple longitudinal beams that extend between the rear end and the front end, and a transverse beam that extends between the first lateral end and the second lateral end. The transverse beam is coupled to one or more of the multiple longitudinal beams. The one or more vents are situated between different pairs of adjacent longitudinal beams of the multiple longitudinal beams.
The foregoing and other aspects and advantages of the present disclosure will appear from the following description. In the description, reference is made to the accompanying drawings that form a part hereof, and in which there is shown by way of illustration one or more exemplary versions. These versions do not necessarily represent the full scope of the disclosure.
The following drawings are provided to help illustrate various features of non-limiting examples of the disclosure, and are not intended to limit the scope of the disclosure or exclude alternative implementations.
Bicycle helmets can help provide a buffer during certain activities. These helmets often include a generally hemispherical body, made of one or more internal support structures and surrounding foam material, with a cavity that receives the head of the user. Straps are coupled to the hemispherical body to be secured around the user's chin, e.g., via a clip. For example, each strap may be wrapped around one of the support structures and secured to itself. However, this engagement adds extra steps to the assembly process prior to encapsulating the support structures in the foam material, does not allow for strap replacement, and continued movement of the straps, e.g., when securing and releasing the straps or during falls or crashes, may affect the foam material around where the straps emerge. In another example, each strap may be coupled to a floating structure embedded within the foam material. However, pulling of the straps, for example during a fall, a crash, or when securing the helmet, can cause significant localized forces adjacent the floating structure. On the other hand, enhanced embodiments described herein provide a helmet including a body having a foam material that defines one or more vents, one or more support structures embedded in the foam material and encircling one or more of the vents, and strap hangers that are coupled to the support structure(s) and accessible from outside the body. Such embodiments permit straps to be tied into the helmet post-assembly and distribute forces from pulled straps throughout the support structures of the helmet rather than localized areas within the foam body.
For example,
Generally, the cage 110 can form a structural support for the helmet 100. For example, in some embodiments, portions of the cage 110 can enclose or encircle the vents 116, 117 and/or portions of the cage 110 can extend through one or more vents 116, 117. As a result, the cage 110 can provide sufficient structural integrity while still allowing the vents 116, 117 to decrease the bulkiness and weight of the helmet 100, and provide airflow paths, allowing air to flow into and out of the vents 116, 117 to facilitate sweat evaporation from the wearer's head.
As shown in
Generally, the longitudinal beams 130 and/or the rims 126, 128 can be spaced apart such that the cage 110, and more specifically, the longitudinal beams 130 and/or the rims 126, 128 help define the vents 116. The transverse beams 132 can be spaced apart and positioned relative to the longitudinal beams 130 and/or the rims 126, 128 such that the cage 110, including the transverse beams 132 and/or the rims 126, 128, and some portions of the longitudinal beams 130, can form a structural support that encircles the vents 116. At the rear end 104, the rims 126, 128, the longitudinal beams 130, and the joists 140 can be spaced apart and positioned relative to each other such that the cage 110 and, more specifically, the rims 126, 128, the longitudinal beams 130, and the joists 140 can help define and encircle the rear vents 117. Furthermore, the transverse beams 132 can be spaced apart and positioned relative to the longitudinal beams 130 and/or the rims 126, 128 such that the cage 110, including some portions of the longitudinal beams 130, can extend through the vents 116 and/or the rear vents 117.
Referring still to
Additionally, the plate 136 is situated on the opposing lateral end 124 of the cage 110, and a second opposite lateral end of each of the transverse beams 132, a portion of the rim 128, and upper portions of the joists 138, 140 are each coupled to the plate 136. The plate 136 can also comprise multiple layers that are coupled to the beams 132, the rim 128, and/or the joists 138, 140 by being sandwiched around, and, e.g., coupled together around, either side of the beams 132, the rim 128, and the joists 138, 140. That is, the plate 136 can include a set of plates comprising a first or outer plate coupled to an outer surface of the cage 110 and a second or inner plate coupled to an inner surface of the cage 110.
As shown in
In some embodiments, as shown in
As shown in
As shown in
In some embodiments, the webbing 150 can extend at least between the clip 148 and the strap receiver 152. Furthermore, in some embodiments, the webbing 150 can extend outward away from the clip 148 and/or the strap receiver 152. For example, as shown in
As noted above, the strap receivers 152 of the strap hangers 142, 144 can receive straps routed therethrough. For example, as shown in
Accordingly, as described above, the strap hangers 142, 144, by being coupled to a structural support like the cage 110, can permit retention forces from the straps to be distributed across the helmet 100 rather than localized to strap attachment areas. While the strap hangers 142, 144 are shown and described herein as having the clips 148 that snap directly onto the cage 110, in some embodiments, the cage 110 can include one or more coupling mechanisms, such as receiving clips (not shown), to receive the strap hangers 142, 144.
Referring now to the body 112 of the helmet 100,
As shown in
Referring back to
Referring now to the shell 114 of the helmet 100,
In some embodiments, the cage 110 and the strap hangers 142, 144 can be together overmolded with the body 112, to deposit the body 112 about the cage 110 and the strap hangers 142, 144 so that portions of the cage 110 and the strap hangers 142, 144 are entirely encapsulated within the body 112. For example, the cage 110 and the strap hangers 142, 144 can be coupled together and placed in a mold (not shown) that has a surface that corresponds to the exterior surface of the body 112. In some cases, portions of the cage 110 and the strap hangers 142, 144 that are to be encapsulated with the material of the body 112 are placed between the interior surfaces of the mold, but not in contact with these surfaces of the mold, while portions of the cage 110 and the strap hangers 142, 144 that are not to be encapsulated with the material of the body 112 engage and contact the interior surfaces of the mold. In this way, when the expandable material (e.g., EPS foam) is injected into the mold, the expandable material will fill in to contact the interior surfaces of the mold thereby encapsulating portions of the cage 110 and the strap hangers 142, 144. However, because the portions of the cage 110 and the strap hangers 142, 144 are already in contact with interior surfaces of the mold, the expandable material is prevented from encapsulating this portion of the cage 110 and the strap hangers 142, 144. Regardless of how the cage 110, the strap hangers 142, 144, and the body 112 are coupled together, once these are assembled, the shell 114 is placed on top of and is coupled to the body 112. In some embodiments, the shell 114 of the helmet 100 can also be placed in the mold with the cage 110 and the strap hangers 142, 144 and molded with the body 112 at the same time as the cage 110 and the strap hangers 142, 144.
In light of the above, some embodiments can provide a helmet 100 including a cage 110 that both encircles one or more vents 116, 117 in order to provide structural support to the helmet 100 and receives strap hangers 142, 144 in order to transfer retention load from straps throughout the helmet 100 rather than at localized attachment areas. In such embodiments, the strap hangers 142, 144 can be coupled to the cage 110 and in-molded in the body 112 at the same time as the cage 110. This can improve manufacturing ease for strap systems, as well as improve accessibility, as the strap receivers 152 may be exposed outside of the body 112, permitting strap installation or replacement post-assembly. The strap hangers 142, 144 can also eliminate the need for additional non-structural components floating in the body 112 for receiving straps, which can improve body volume and EPS foam flow during assembly of the body 112.
It should be noted that the cage 110, the body 112, and/or the shell 114 can include different or other features without departing from the scope of the invention. For example, the strap hangers 142, 144 can be incorporated with cages of any of the helmets described in international application no. PCT/US2020/018956, filed Mar. 4, 2022, the entire contents of which is incorporated herein by reference.
It should further be noted that other structural support elements embedded in a body and that encircle vents of a helmet may be also used as load transfer elements for strap hangers. As but one example,
As shown in
In some embodiments, the helmet 300 can include strap hangers, similar to the strap hangers 142, 144 of
The present disclosure has described one or more embodiments, and it should be appreciated that many equivalents, alternatives, variations, and modifications, aside from those expressly stated, are possible and within the scope of the invention. For example, in some embodiments, any of the above-described cages may be entirely encapsulated by a body. Additionally, it should be noted that features described with respect to one embodiment may be incorporated into another embodiment. For example, in some embodiments, the helmet 100 or one or more elements of the helmet 100 can be similar to the helmet 300, or the helmet 300 or one or more elements of helmet 300 can be similar to the helmet 100. It is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the accompanying description or illustrated in the accompanying drawings. Given the benefit of this disclosure, one skilled in the art will appreciate that the disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
As used herein, unless otherwise limited or defined, discussion of particular directions is provided by example only, with regard to particular embodiments or relevant illustrations. For example, discussion of “top,” “front,” or “back” features is generally intended as a description only of the orientation of such features relative to a reference frame of a particular example or illustration. Correspondingly, for example, a “top” feature may sometimes be disposed below a “bottom” feature (and so on), in some arrangements or embodiments. Further, references to particular rotational or other movements (e.g., counterclockwise rotation) is generally intended as a description only of movement relative a reference frame of a particular example of illustration. Additionally, as used herein, unless otherwise defined or limited, directional terms are used for convenience of reference for discussion of particular figures or examples. For example, references to downward (or other) directions or top (or other) positions may be used to discuss aspects of a particular example or figure, but do not necessarily require similar orientation or geometry in all installations or configurations.
In some implementations, devices or systems disclosed herein can be utilized or installed using methods embodying aspects of the disclosure. Correspondingly, description herein of particular features, capabilities, or intended purposes of a device or system is generally intended to inherently include disclosure of a method of using such features for the intended purposes, a method of implementing such capabilities, and a method of installing disclosed (or otherwise known) components to support these purposes or capabilities. Similarly, unless otherwise indicated or limited, discussion herein of any method of manufacturing or using a particular device or system, including installing the device or system, is intended to inherently include disclosure, as embodiments of the disclosure, of the utilized features and implemented capabilities of such device or system.
As used herein, unless otherwise defined or limited, ordinal numbers are used herein for convenience of reference based generally on the order in which particular components are presented for the relevant part of the disclosure. In this regard, for example, designations such as “first,” “second,” etc., generally indicate only the order in which the relevant component is introduced for discussion and generally do not indicate or require a particular spatial arrangement, functional, or structural primacy or order.
As used herein, unless otherwise defined or limited, the term “about” or “approximately” or “substantially” refers to variation in the numerical quantity that may occur, for example, through typical measuring and manufacturing procedures used for helmets or other articles of manufacture that may include embodiments of the disclosure herein; through inadvertent error in these procedures; through differences in the manufacture, source, or purity of the ingredients used to make the compositions or mixtures or carry out the methods; and the like. Throughout the disclosure, the terms “about,” “approximately,” and “substantially” refer to a range of values ±20% of the numeric value that the term precedes.
This discussion is presented to enable a person skilled in the art to make and use embodiments of the disclosure. Given the benefit of this disclosure, various modifications to the illustrated examples will be readily apparent to those skilled in the art, and the principles herein can be applied to other examples and applications without departing from the principles disclosed herein. Thus, embodiments of the disclosure are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein and the claims below. The accompanying detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected examples and are not intended to limit the scope of the disclosure. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of the disclosure.
Various features and advantages of the disclosure are set forth in the following claims.
This application claims priority under 35 U.S.C. § 119 to U.S. Provisional Patent Application No. 63/343,925 filed on May 19, 2022, the entire contents of which is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63343925 | May 2022 | US |
