Note: Descriptions are shown in the official language in which they were submitted.
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1
A NOVEL PROTECTIVE HELMET
TECHNICAL FIELD
The present invention relates to protective helmets, in particular sports and
bicycle helmets and
manufacturing thereof.
BACKGROUND
Using a protective helmet is essential for activities such as cycling, hockey,
football, rock
climbing, skiing, construction, military, or other helmet-required activities.
Helmets are very
effective in reducing the risk of head injury and concussion. To reduce the
risk of head injury
and concussion, a helmet needs to mitigate both linear forces (caused by
linear acceleration),
and rotational forces (caused by rotational acceleration and rotational
velocity) applied to the
head during impact. In the past, helmets were mainly designed to reduce the
linear forces as
standards did not take into account the rotational forces for the purpose of
certification.
However, research studies have shown that rotational forces of the head are
one of the key
factors behind head injury and concussion. Therefore, to enhance the safety of
the wearers,
when designing a helmet reducing both the linear forces and rotational forces
need to be
considered. Foams such as expanded polystyrene (EPS) are widely used in
protective
equipment such as helmets due to their low cost, high shock absorption, good
durability, and
excellent conformability in moulding. However, manufacturing helmets with
rigid foam such as
EPS has a number of issues. One issue is related to designing helmets with
better shock
absorption. In current helmet designs, creating cavities and channels is only
possible in the
direction of the mould's opening and closing unless the male part of the mould
is a multiple-
piece male tool. Using multiple-piece mould (e.g. mould with sliders) can be
expensive and
labour-intensive, has limitations and results in helmets that are heavier and
do not necessarily
have better overall shock absorption. Another issue is related to having an
embedded
mechanism for mitigating the rotational forces. Most designs use add-on
mechanisms to deal
with rotational forces which may not be the best way of addressing the issue
as it increases the
weight of the helmet. Therefore, any helmet design and manufacturing
methodology that could
address the aforementioned issues would be desirable to the helmet industry.
In conventional helmets that are made with foams such as Expanded Polystyrene
(EPS) and its
bio-degradable version Expanded Polylactic Acid (EPA), the helmets are mostly
made using a
single moulding with a single density for the shock-absorbing liner. In some
newer designs,
helmets are made with multiple layers of foams with different densities that
are laid on top of
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each other employing multiple moulding processes. In helmets with both single
and multiple
density shock-absorbing liners, there are restrictions in the direction,
shape, and location of the
cavities that are introduced in a helmet. At the same time, multi-density
shock absorption does
not provide an effective mechanism for reducing rotational forces. Designing a
helmet with
hollow compartments, cavities or channels that are not aligned with the
pulling direction of the
male and female moulds significantly increases the cost of labour and overhead
of
manufacturing a helmet. In addition, helmet toolings that are made of multiple
parts and consist
of sliders for the male mould are less durable and their life cycle is shorter
than single-piece
male moulds. Using sliders has its own limitations and shock-absorbing liners
with closed
cavities, and open cavities facing the outer shell are not possible to make or
making them is not
economically viable. In addition, for every different pulling direction of the
cavity, a new slider is
needed that usually are manually handled.
SUMMARY
One general aspect provides a protective helmet having an outer shell having
an inward
surface; a first set of shock-absorbing liners attached to the inward surface
of the outer shell; a
second set of shock-absorbing liners having multiple parts that can move and
deform
independently of each other when an impact force is applied to the outer shell
of the helmet;
and a fitting liner covering one or more of the parts of the second set of
shock-absorbing liners,
attachment means connecting an inward surface of the first set of shock-
absorbing liners to the
second set of shock-absorbing liners; and where a contact area between the
first set of shock-
absorbing liners and the second set of shock-absorbing liners is smaller than
an inner surface
area of the first set of shock-absorbing liner.
Implementations may include one or more of the following features. The
protective
helmet where each of the one or more parts of the second set of shock-
absorbing liners are
separately attached to the first set of shock-absorbing liners using at least
one of the attachment
means. The attachment means are made of any mechanical or chemical attachment
means
such as hook-and-loop fastener, pin, snap pin, snap pin basket, snap fastener,
latch-and-hook
fastener, clips, hinge, press-fitting, hook plastic insert and loop rubber,
rubber holder, mesh
holder, silicone rubber holder, tie, connector, spring, buckle, heat-seal,
sewing, fusion, elastic,
fitting, adhesive, insert, screw, railing, button, buttonhole, rivet, or a
combination thereof. The
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attachment means provide a finite amount of play in the connection between of
the second set
of shock-absorbing liners relative to the first set of shock-absorbing liners.
The attachment
means further attaches to the fitting liner The attachment means is flexible
and elongates
elastically under the impact force, or plastically when the impact force
exceeds a threshold. The
attachment means are frangible in order to rupture when the impact force
exceeds a second
threshold to allow unrestricted movement between the first set and the second
set of shock-
absorbing liners. The first set of shock-absorbing liners may include a low
friction layer. The
either of the low friction layers may include a lubricant, plastic, rail,
sliding groove, wax, powder,
polymer, elastomer, rubber, polycarbonate (pc), acrylonitrile butadiene
styrene (abs), carbon
fiber, silicone rubber, silicone lubricant, fluid-filled compartment, fabric,
fiber, or a combination
thereof. The second set of shock-absorbing liners may include a low friction
layer. The
attachment means elongates, ruptures or dislocates during the impact force to
allow the second
set of shock-absorbing liners to move relative to the first set in order to
reduce rotational and
linear forces applied to the head during impact The second set of shock-
absorbing liners are
made of the same materials with a similar or different density than the first
set of shock-
absorbing liners. The second set of shock-absorbing liners are made of
different materials than
the first set of shock-absorbing liners. The two sets of shock-absorbing
liners may include
micro-porosity, macro-porosity, thin-walled structure, fluid-filled
compartment, truss structure,
lattice structure, auxetic structure, channeled structure, open cavity, closed
cavity, hole, or a
combination thereof. The first sets of shock-absorbing liners, or the second
set of shock-
absorbing liners, or both may include at least some of the attachment means.
One or more
shapes and sizes are defined to be used repeatedly for all the parts of the
second set of shock-
absorbing liners.
One general aspect includes a method of manufacturing a protective helmet. The
method includes separately making a) a first set of shock-absorbing liners and
b) a second set
of shock-absorbing liners, the second set of shock-absorbing liners having
multiple parts;
attaching the first set of shock-absorbing liners to each of the multiple
parts of the second set of
shock-absorbing liners using attachment means, fixing an outer shell at its
inward surface to the
first set of shock-absorbing liners, and covering a fitting liner around one
or more of the multiple
parts of the second set of shock-absorbing liners.
DESCRIPTION OF THE DRAWING
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The foregoing aspects of the present disclosure will become more readily
appreciated as the
same will become better understood by reference to the following detailed
description, when
taken in conjunction with the accompanying drawing, wherein:
FIGURE 1 is a cross-section of a helmet comprising two sets of shock-absorbing
liners in
accordance with a number of embodiments.
FIGURE 2A is a side view of a helmet in accordance with a number of
embodiments.
FIGURE 2B is a bottom view of a helmet in accordance with a number of
embodiments.
FIGURE 20 is a cross-section of a helmet along section A-A from Figure 2B in
accordance with
a number of embodiments.
FIGURE 3A is a side view of the first set of shock-absorbing liners of a
helmet in accordance
with a number of embodiments.
FIGURE 3B is a side view of the second set of shock-absorbing liners of a
helmet and its fitting
liner in accordance with a number of embodiments.
FIGURE 30 is an exploded illustration of connectors for attaching the second
set of shock-
absorbing liners and the fitting liner to the first set of shock-absorbing
liners in a helmet in
accordance with a number of embodiments.
FIGURE 4A is a cross-section (Section A-A of FIGURE 3A) of the first set of
shock-absorbing
liners of a helmet.
FIGURE 4B shows a cross-section (Section B-B of FIGURE 3-B) of the side view
the second
set of shock-absorbing liners of a helmet.
FIGURE 4-C shows the attachment means associated with the cross-section C-C
(shown in
FIGURE 3-C) used for attaching the second set of shock-absorbing liners and
the fitting liner to
the first set of shock-absorbing liners in a helmet.
DETAILED DESCRIPTION
In the following section, specific details are explained to provide an in-
depth understanding of
the exemplary embodiments of the present invention. It will be apparent to one
familiar with the
art that the embodiments shown may be realized without embodying every
specific detail. The
embodiments of the present invention may also employ any combination of
features described
below. The following description provides illustrations of a novel helmet
design and method of
moulding a helmet to include the claimed features.
The following description provides illustrations of a novel helmet design.
The present disclosure describes a novel protective helmet design that allows
helmet designers
and manufacturers to create more advanced designs with cavities, converging
walls, and
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movable parts inside a helmet to reduce both linear and rotational forces
applied to the head
during an impact and as a result, reduce the risk of head injury and
concussion.
In one embodiment, the design of the shock-absorbing liner of a helmet is
divided into two sets
(called "the two sets"). The first set of shock-absorbing liners (also called
"the first set") is
5 manufactured using a thinner layer of the shock-absorbing liner than a
comparable conventional
helmet. Then, the second set of shock-absorbing liners (also called "the
second set") is
separately manufactured. The second set consists of multiple parts that are
attached to the
designated areas on the surface of the first set that is facing the wearer's
head. When the
helmet is impacted, the parts of the second set of shock-absorbing liners can
move and deform
independently of each other.
The attachment means used to attach the first set, the second set, and the
fitting liner to one
another can be any mechanical or chemical attachment means or fasteners known
in the
industry.
The present disclosure introduces a cost-effective design and manufacturing
method that
creates helmets that are light-weighted and perform better compared to the
conventional helmet
designs in terms of reducing linear and rotational forces applied to the head
during an impact.
In an aspect, the present disclosure explains ways for designing and
manufacturing a helmet
including open cavities, close cavities, converging walls, thin-walled
structures, fluid-filled
compartments, and deep channels in various directions on the inward surface of
the helmet
where it is facing the wearer's head without a need to use labour-intensive
methods such as
using a multiple-piece male mould (i.e. mould with sliders) for manufacturing
the helmets.
In an embodiment, the present disclosure describes a novel design and its
manufacturing
method for helmets to improve them in terms of protection, weight, cost, and
ventilation. Such
characteristics are desirable in the helmet industry.
The method also allows manufacturing helmets while consuming less raw
materials for the
shock-absorbing liner which is cost-effective and better for the environment.
In an embodiment, the parts of the second set have different shapes,
materials, sizes, or
densities which allow customizing the helmet design in terms of improving the
head protection,
reducing the weight of a helmet, embedding electronics or battery inside a
helmet, or other
design requirements for a helmet.
Using two sets of shock-absorbing liners gives more freedom to helmet
designers and allows
them to design helmets optimally. For instance, there are areas in a helmet
that due to the
geometry and moulding constraints cannot be optimally designed and would
usually comprise
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more shock-absorbing materials than needed. By using two sets of shock-
absorbing liners, it is
possible to improve the design of these areas.
In addition, by using two sets of shock-absorbing liners, it is possible to
easily alter the design
when needed. For instance, if preliminary tests show that the helmet
performance needs to be
improved in certain areas to pass the standard certification, it is possible
to only modify the
design of one or more parts of the second set by changing their density,
material, shape, size or
configuration to resolve the issue without getting involved in a lengthy and
costly process of
updating the entire mould of the shock-absorbing liner of a helmet.
In an embodiment, one or more parts of the second set that are attached to the
first set can
move and deform independently of the rest of the parts of the second set when
the force applied
to the helmet exceeds a certain limit. In most impact scenarios, only a
limited area of the shock-
absorbing liner is mainly engaged and damaged. Allowing only the parts of the
second set
located on the impacted area to move and deform independently enhances the
helmet
performance in mitigating the rotational and linear forces applied to the head
during an impact.
In one embodiment, the parts of the second set are made of the same type of
materials with
different density than the first set. This embodiment allows designing helmets
by varying the
density of the second set to enhance the helmet performance for various impact
intensities.
Since the moulding process of the second set is separate from the moulding
process of the first
set, it is possible to change the density of the second set as needed without
applying any
changes to the design of the first set. For instance, the first set can be
made using higher
density EPS than the second set. This allows the helmet to perform better for
both high-speed
and low-speed impacts.
In one embodiment, the parts of the second set of shock-absorbing liners are
made of a
different material than the first set of shock-absorbing liners. For instance,
the first set of shock-
absorbing liners is made of EPS or EPA, and the second set is made of thin-
walled plastic
structures such as honeycomb or a combination of different materials and
structures.
In an embodiment, all the parts of the second set used for a helmet have
similar shapes or
sizes. The embodiment can reduce the manufacturing cost of the helmet.
In an embodiment, some of the parts of the second set used for a helmet have a
similar shape
or size.
In an embodiment, the inward surface of the first set that faces the wearer's
head is designed to
allow using similar shapes and sizes for some or all of the parts of the
second set of shock-
absorbing liners. The embodiment can reduce the manufacturing cost of
producing the helmet.
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In an embodiment, a helmet comprises an outer shell, the first set, the second
set,
attachment means for attaching the second set to the first set, a fitting
liner, and attachment
means for attaching the fitting liner to the helmet.
In an embodiment, the attachment means used for attaching the second set to
the first set also
attaches the fitting liner to the second set of shock-absorbing liners.
The outer shell is considered to be the outward surface of the first set
facing away from the
wearer's head.
In one embodiment, the deformation and compression of the second set and the
first set result
in improving the helmet performance by reducing the linear and rotational
forces applied to the
head during an impact.
In an embodiment, when the applied force to the helmet exceeds a certain limit
the second set
can experience a movement relative to the first set The limit depends on
various factors such as
shape and location of the second set, the type of attachment means used for
attaching the
second set to the first set, the shape of the first set, the impact force
intensity and direction, and
where the force was applied to the helmet.
In an embodiment, the movement of the second set relative to the first set is
constrained by the
type and number of the attachment means used for attaching the second set to
the first set.
In one embodiment, the second set is firmly attached to the first set of shock-
absorbing liners,
but the fitting liner is attached such that the head and the fitting liner can
move relative to the
rest of the helmet if the applied force to the helmet exceeds a certain limit.
The embodiment can
include a low friction layer between the fitting liner and the second set to
facilitate the relative
movement between the fitting liner and the rest of the helmet. According to
this embodiment, the
deformation and compression of the first set and the second set, and the
movement of the head
and fitting liner relative to the rest of the helmet enhance the helmet
performance by reducing
the linear and rotational forces applied to the head during an impact.
In an embodiment based on the previous embodiment, the attachment means used
for
attaching the fitting liner to the first set or the second is such that they
can dislocate or elongate
during impact to allow the fitting liner to move relative to the second set.
For instance, the
attachment means can comprise a button, buttonhole in the fitting liner,
elastic connector that is
attached to the first set, the second set, or both.
In an embodiment, a low friction layer is placed between the first set and the
second set to allow
a relative motion between the two sets when the applied force to a helmet
exceeds a certain
limit.
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In an embodiment, a low friction layer is placed between the second set and
the fitting liner to
allow a relative motion between the second set and the fitting liner when the
applied force to a
helmet exceeds a certain limit.
In an embodiment, the low friction layer comprises a lubricant, plastic,
polymer, elastomer,
polycarbonate (PC), acrylonitrile butadiene styrene (ABS), wax, powder, carbon
fiber, rail,
sliding groove, rubber, fabric, fiber, silicone rubber, silicone lubricant, or
a combination thereof.
In an embodiment, the low friction layer between the two sets is a fluid-
filled compartment.
In one embodiment, the second set is attached to the first set of shock-
absorbing liners such
that if a force applied to the helmet exceeds a certain limit the second set
and the fitting liner
can move temporarily or permanently relative to the first set. This embodiment
improves the
ability of the helmet to reduce both linear and rotational forces applied to
the head during
impact.
In an embodiment, the fitting liner and the head can move in any direction
relative to the second
set of shock-absorbing liners or the rest of the helmet when the applied force
to a helmet
exceeds a certain limit.
In an embodiment, the low friction layer is partly or entirely part of the
first set.
In an embodiment, the low friction layer is partly or entirely part of the
second set.
In an embodiment, the low friction layer is partially part of the first set,
and partially part of the
second set.
In an embodiment, the low friction layer is an independent layer placed
between the first set and
the second set.
In an embodiment, the low friction layer is a layer between the second set and
the fitting liner.
In an embodiment, the attachment means that attaching the first set to the
second set allows a
discreet relative movement between the first set and the second set when the
applied force to
the helmet exceeds a certain limit. There may be a finite amount of play in
the attachment
between sets of shock-absorbing liners to permit this finite movement. The
finite relative
movement can enhance the protection of the helmet by reducing the linear and
rotational forces
apply to the head during most impacts on the helmet.
In an embodiment, the attachment means are frangible and designed to rupture
or disconnect
when the applied force to the helmet exceeds a certain limit. The rupture or
disconnection of the
attachment means can further enhance the helmet performance.
In an embodiment, a low friction layer is placed between the two sets. The low
friction layer
facilitates the relative movement between the two sets when the applied force
to the helmet
exceeds a certain limit.
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In an embodiment, the attachment means controls the motion caused by the low
friction layer in
the presence of an impact force. The embodiment allows the second set and the
fitting liner to
move finitely relative to the first set to enhance the helmet performance
during an impact.
In an embodiment, the attachment means that attach the fitting liner to the
first set and the
second set elastically or plastically elongates and allows a finite relative
movement between the
fitting liner and the rest of the helmet when the applied force to the helmet
exceeds a certain
limit. The finite movement can enhance the protection of the helmet by
reducing the linear and
rotational forces apply to the head during most impacts on the helmet. A
sufficiently large force
can result in one or more of the attachment means being ruptured or
disconnected.
In an embodiment, the deformation of the two sets reduces the linear forces
and rotational
forces applied to the head when the helmet is impacted.
In an embodiment, the deformation and dislocation of the second set further
reduce the linear
forces and rotational forces applied to the head when the helmet is impacted.
In an embodiment, the deformation and movement of the second set and the
fitting liner relative
to the first set further reduce the linear forces and rotational forces
applied to the head when the
helmet is impacted.
In an embodiment, the fitting liner is one piece that covers all the parts of
the second set.
In an embodiment, the fitting liner comprises multiple pieces that cover one
or more parts of the
second set.
In an embodiment, one piece of the fitting liner covers multiple parts of the
second set.
In an embodiment, the fitting liner covers some or all of the first set and
the second set.
In one embodiment, the first set, the second set, and the fitting liner are
attached to one another
using any mechanical or chemical attachment means or fasteners such as hook-
and-loop
fastener, pin, snap pin, snap pin basket, snap fastener, latch-and-hook
fastener, clips, hinge,
press-fitting, hook plastic insert and loop rubber, rubber holder, silicone
rubber holder, tie,
connector, mesh holder, spring, buckle, heat-seal, sewing, fusion, elastic,
fitting, adhesive,
insert, screw, railing, button, buttonhole, rivet, or a combination thereof.
In an embodiment, the attachment means or parts of them are moulded with the
first set or the
second set or both.
In an embodiment, the attachment means or part of them are included in the
fitting liner. For
example, the fitting liner can comprise the buttonholes needed for attaching
to the buttons as a
part of the attachment means.
In an embodiment, the attachment means or parts of them are added to the first
set or the
second set or both after the moulding process.
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In one embodiment, one or more parts of the second set of shock-absorbing
liners are
detachable from the first set.
In one embodiment, the fitting liner is detachable from the first set or the
second set or both.
In an embodiment, the second set of shock-absorbing liners is made in a
variety of shapes,
5 materials, and sizes to provide a better fit or better protection for the
wearer's head.
In an embodiment, one or more shapes and sizes are defined to be used for all
the required
parts for the second set. By using only one or more parts repeatedly for all
the needed parts of
the second set, it is possible to reduce the cost of manufacturing the helmet.
In one embodiment, by changing the size, shape, and configuration of the
second set, it is
10 possible to change the size of the helmet and make it suitable for other
sizes of the head. For
example, the first set and the outer shell of a helmet are designed for the
large size head, and
by changing the size and shape of the parts of the second set, it is possible
to make the helmet
suitable for the medium size head. Such an embodiment can reduce the cost of
manufacturing.
In an embodiment, one or more parts of the second set of shock-absorbing
liners are
permanently attached to the first set.
In one embodiment, the surface of the first set of shock-absorbing liners that
is facing the
second set is covered by a layer of polymer, plastic, elastomer, metal,
rubber, silicone rubber,
PC, carbon fiber, ABS, lubricant, silicone lubricant, fabric, fiber, or a
combination thereof.
In one embodiment, the first set and the second set of shock-absorbing liners
comprise EPS,
EPA, ABS, PC, Kevlar, titanium, polymer, plastic, polyurethane, foam, textile,
elastomer,
composite, resin, shock-absorbing foam, rubber, fiber, silicone, non-Newtonian
material, organic
material, fluid-filled compartment, metal, or a combination thereof.
In one embodiment, the first set, or the second set or both are reinforced
during or after
manufacturing by means of reinforcing materials such as fabric, fiber,
plastic, Kevlar, carbon
fiber, PC, ABS, metal, or a combination thereof. For example, the surface area
of the second
set that faces the first set is moulded with PC sheets.
In an embodiment, the protective helmet is used for any helmet-required
activities such as
cycling, motorcycling, skiing, rock-climbing, military, football, hockey, all-
terrain vehicle (ATV),
and construction.
The approach disclosed herein may be used to make various protection equipment
where the
protected object is any part of the body or any other object that requires
protection against
impact.
In one embodiment, the first set, the second set, or both or parts of them are
made by using
additive manufacturing methods.
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In one embodiment, the surface of the second set that faces the wearer's head
is considered as
the fitting liner.
In one embodiment, the parts of the second set of shock-absorbing liners move
in the same or
different directions during an impact on the helmet. Since the parts of the
second set are
attached to the first set separately, depending on the location, direction,
and intensity of the
impact force the parts can move in directions that are not necessarily the
same for all the parts
of the second set.
In an embodiment, there are more than two sets of shock-absorbing liners and
use the same
methods of attachment described herein for attaching the second set to the
first set, the third set
is attached to the second set, and the fourth set attached to the third set,
and so forth.
In one embodiment, the first set and the second set of shock-absorbing liners
or part of them
are made of structures having geometries, such as trusses, hexagonal, hollow
compartments,
cylindrical, macro-cavity, micro-cavity, foam, open cavity, closed cavity,
channelled structure,
fluid-filled compartment, lattice, thin-walled structure, auxetic structure,
collapsible geometries or
a combination thereof.
The manufacturing process includes designing the two sets of shock-absorbing
liners. The
shock-absorbing liner of the helmet is divided into two sets with two
different thicknesses, called
the first set and the second set. The thickness of each set is determined
based on the material,
density, and structure used for each set of shock-absorbing liners. For
bicycle helmets made
from EPS, the thickness for the first set and the second set is between 5mm to
35mm. The
thickness of each area of the first set and set second varies throughout
different areas of the
helmet to create the protection needed during impact. It is also possible to
use thinner or thicker
EPS for certain areas of the first set or the second set by varying the
density of the EPS
between 60g/L to 120g/L. Using materials or structures other than EPS will
need to be tested to
find the proper thickness for a target helmet type Then, the mould of the
first set of shock-
absorbing liners is designed to have the required thickness and then the first
set and outer shell
of the helmet are moulded together. In the next step, based on the
specifications of the design,
the parts of the second set are moulded separately. In the last step, the
parts of the second set
and the fitting liner are attached to the first set by the attachment means.
Other techniques
besides moulding can also be used for manufacturing the two sets such as
layering, additive
manufacturing, injection moulding or any other method known in the industry
for making a
helmet.
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In one method of the manufacturing process, the attachment means or parts of
the attachment
means are moulded during the moulding process of the first set and the outer
shell of the
he
In one method of the manufacturing process, the attachment means or parts of
the attachment
means are moulded during the moulding process of the second set.
In one method of the manufacturing process, the attachment means or parts of
the attachment
means are made separately from moulding the two sets of the shock-absorbing
liners.
In one method of the manufacturing process, a low friction layer or parts of
it are moulded
during the moulding process of the second set.
In one method of the manufacturing process, a reinforcing layer or parts of it
are moulded during
the moulding process of the second set. For example, a PC sheet can be moulded
with the
second set where it faces the first set. The moulded PC sheet with the second
set can act both
as a reinforcing layer for the second set and a low friction layer to reduce
friction between the
two sets. Another example is using a PC sheet to be moulded with the second
set where it
faces the fitting liner. The moulded PC sheet with the second set can act both
as a reinforcing
layer for the second set and a low friction layer to reduce friction between
the second set and
the fitting liner.
In one method of the manufacturing process, a reinforcing layer or parts of it
are moulded during
the moulding process of the first set.
In one method of the manufacturing process, a low friction layer or parts of
the low friction layer
are moulded during the moulding process of the first set and the outer shell
of the helmet. For
instance, the surface of the first set that faces the second set can be
covered by a layer of
polycarbonate, lubricant, or both.
In one method of the manufacturing process, a low friction layer or parts of
the low friction layer
are made independent of the two sets of shock-absorbing liners.
FIGURE 1 discloses multiple embodiments and shows the cross-section of the
helmet 101 (side
view) worn on the head 100 comprises the outer shell 103, and the first set of
shock-absorbing
liners (also called the first set") 102 that is attached to the outer shell
103 at one or more
locations. The second set of shock-absorbing liners (also called "the second
set") 104
comprises multiple parts that one or more of them are separately attached to
the first set of
shock-absorbing liner 102 by mechanical or chemical attachment means
including, but not
limited to, hook-and-loop fastener 109, inserts 107, adhesive, snap pin 111
and snap pin basket
110, anchor 108, or any other attachment means or fasteners known in the
industry for
attaching the second set 104 to the first set 102. The second set 104 can also
comprise layer
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118 as a low friction layer to allow the second set 104 to move relative to
the first set 102 when
a force applied to the helmet 101 exceeds a certain limit. The layer 118 as a
low friction layer
can be also attached to the first set 102 (not shown in FIGURE 1) or attached
to both the first
set 102 and the second set 104 (not shown in FIGURE 1). The layer 118 as a low
friction layer
can cover one or more surfaces of the first set 102 (not shown in FIGURE 1) or
the second set
104.
The second set 104 is covered at one or more locations by a fitting liner 105
where the fitting
liner 105 contacts the head 100 at one or more locations. The attachment means
used for
attaching the fitting liner 105 to the second set 104 or the first set 102 are
any mechanical or
chemical attachment means such as hook-and-loop 113, adhesive 115, sewing 116,
button 112
anchored to the second set 104, button 114, buttonhole (not shown in FIGURE 1)
in the fitting
liner 105, and connector 121 to attach the fitting liner 105 to the first set
102 by anchor 108
through the opening 126 in the second set 104.
To better show the details, purposely, some of the parts in FIGURE 1 are shown
farther than
normal from each other. As a result, gaps between different components should
not be
interpreted as an error or limitation in the presented invention In addition,
a helmet normally
comprises other parts such as a retention system (chin strap), adjustment
mechanism (ratchet),
and other accessories that are not shown to keep the description and drawings
simple and
uncluttered from prior art parts that are not the focus of this invention.
However, such
accessories can be considered as part of the helmet.
In an embodiment according to FIGURE 1, the finite relative movement between
the second set
104 and the first set 102 during impact to the helmet 101 is facilitated by
the layer 118 as a low
friction layer and controlled by the anchor 108, the connector 121, the
opening 126 in the
second set 104, the fitting liner 105, button-hole in the fitting liner (not
shown in FIGURE 1), and
the button 114. The connector 121 is made of an elastic material such as
rubber or spring and it
is attached to the fitting liner 105 by an attachment means such as button 114
and a buttonhole
(not shown in FIGURE 1) in the fitting liner 105 at one end, and at the other
end, the connector
121 is attached to the first set 102 by the anchor 108. The embodiment allows
the second set
104 to dislocate and move finitely when the impact force applied to the helmet
101 exceeds a
certain limit. The duration of an impact is very short. For instance, for a
bicycle helmet made of
EPS, the duration is between 0.007 seconds (7ms) to 0.015 seconds (15ms).
Since the duration
is very short, the movement of the head is very finite. Normally less than
15mm. However, since
the acceleration/deceleration is very high (between 40g to 400g and 1krad/s^2
and 10krad/s^2),
the force applied to the head is very injurious and can result in severe head
trauma. The
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allowed finite movement between the first set 102, the second set 104, and the
fitting liner 105
and compression of the first set 102 and the second set 104 during impact can
significantly
reduce the force applied to the head 100. As a result of the finite movement
of the second set
104 relative to the first set 102, the rotational and linear forces applied to
the head 100 during
an impact on the helmet 101 will be mitigated.
In an embodiment according to FIGURE 1, the connector 121 circles around the
second set 104
(not shown in FIGURE 1), instead of going through them similar to opening 126.
In an embodiment according to FIGURE 1, the layer 118 is a low friction layer
made of materials
such as a lubricant, polymer, elastomer, plastic, rail, sliding groove, wax,
powder, PC, ABS,
Teflon, carbon fiber, rubber, silicone rubber, silicone lubricant, fluid-
filled compartment, fabric,
fiber, foam, or a combination thereof. In an embodiment according to FIGURE 1,
one or more
surfaces of the second set 104 are covered by a reinforcing layer such as the
layer 117 or the
layer 118 as a reinforcing layer to reinforce the structure of the second set
104. The layer 117 or
the layer 118 as a reinforcing layer can be made of materials such as polymer,
plastic,
thermoplastic, organic materials, metal, fiber, fabric, PC, carbon fiber,
resin, ABS, Kevlar,
titanium, or other common materials used for a helmet The layer 117 or the
layer 118 as a
reinforcing layer can also be in form of a reinforcing means which is partly
or entirely embedded
inside the second set 104 similar to the concept of reinforcing bar in
concrete or plastic keel in
the EPS helmets. The layer 117 or the layer 118 as a reinforcing layer can
cover a portion or all
surfaces of the second set 104.
In an embodiment according to FIGURE 1, the layer 117 and the layer 118 as a
reinforcing layer
can comprise openings to allow the connector 121 to pass through the opening
126 in the
second set 104.
In an embodiment according to FIGURE 1, the layer 117 is both a low friction
layer and a
reinforcing layer for the parts of the second set 104. For example, the layer
117 can be made of
a polycarbonate sheet with or without a layer of lubricant to enforce the
second set 104 and also
facilitate the movement of the second set 104 relative to the fitting liner
105.
In an embodiment according to FIGURE 1, the layer 118 is both a low friction
layer and a
reinforcing layer for the parts of the second set 104. For example, the layer
118 can be made of
a polycarbonate sheet with or without a layer of lubricant to enforce the
second set 104 and also
facilitate the movement of the second set 104 relative to the first set 102.
In an embodiment according to FIGURE 1, the layer 117 reduces the friction
between the fitting
liner 105 and the second set 104 and it allows the fitting liner 105 and the
head 100 to have a
relative movement with respect to the rest of the helmet 101 when an impact
force applies to the
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helmet 101. This relative movement can enhance the performance of the helmet
101 by
reducing the linear and rotational forces apply to the head 100 during an
impact.
In an embodiment according to FIGURE 1, the layer 117 is a lubricant, polymer,
elastomer,
fabric, plastic, wax, powder, PC, ABS, carbon fiber, Teflon, or a combination
thereof, or any
5 other low friction layers.
In an embodiment according to FIGURE 1, the second set 104 comprises multiple
parts that can
move and/or deform independently of each other when the force applied to the
helmet exceeds
a certain limit. The limit normally is around 10g and 0.5krad/sA2, depending
on the density and
structure of the material used for the second set 104.
10 In an embodiment according to FIGURE 1, the attachment means such as the
attachment
means 106 to 111 allow the second set 104 and the fitting liner 105 to have
finite movements
relative to the first set 102 when the applied force to the helmet exceeds a
certain limit. That is,
the second set 104 is free to move a small distance before it is bounded by
the attachment
means 106 to 111.
15 In an embodiment according to FIGURE 1, the finite movements of the
parts of the second set
104 relative to the first set 102 during an impact enhance the helmet 101
performance by
reducing linear and rotational forces applied to the head 100.
In an embodiment according to FIGURE 1, the finite movements of the second set
104 relative
to the first set 102 during an impact can be translational, rotational or
both.
In an embodiment according to FIGURE 1, the anchor 108, insert 107, snap pin
111, snap pin
basket 110, button 112, button 114, and the connector 121 are partly or
entirely made of rigid or
flexible materials such as plastic, polymer, fiber, fabric, rubber, elastic,
silicone rubber, metal, or
a combination thereof.
In an embodiment according to FIGURE 1, the anchor 108 can be any other
attachment means
described herein.
In an embodiment according to FIGURE 1, the presence of the hollow compartment
119, the
open cavity 120, indentation 125, opening 126, recess 127, and recess 128
results in a better
shock-absorption of the first set 102, and the second set 104 during an
impact.
In an embodiment according to FIGURE 1, the hollow compartment 119, and the
open cavity
120 comprise or are filled with another type of shock-absorbing materials to
create multi-stage
shock-absorption for the second set 104.
In an embodiment according to FIGURE 1, the hollow compartment 119, the open
cavity 120,
indentation 125, opening 126, recess 127, and recess 128 can have any shape,
size, direction,
or form based on the design requirements.
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In an embodiment according to FIGURE 1, the second set 104 includes open
cavity 120, hollow
compartment 119, or any other macro-cavities, closed cavities, fluid-filled
compartments, thin-
walled structure or a combination thereof to improve the energy absorption of
the second set
104 during an impact to the helmet 101.
In an embodiment according to FIGURE 1, the first set 102 and the second set
104 comprise
EPS, EPA, plastic, polymers, rubber, silicone rubber, elastomer, resin, metal,
fiber, fabric, PC,
carbon fiber, ABS, foam, Kevlar, or a combination thereof, or any other
materials known in the
industry for making a helmet.
In an embodiment according to FIGURE 1, the first set 102 and second set 104
comprise
structures such as a thin-walled structure, honeycomb structure, auxetic
structure, fluid-filled
compartment, collapsible structure, macro-cavity structure, micro-cavity
structure, closed-cavity
structure, open-cavity structure, or a combination thereof. Since the two sets
are made in
separate processes, different densities, structures, or materials can be used
for the first set 102,
and the second set 104.
In an embodiment according to FIGURE 1, the first set 102. or the second set
104, or both are
made by additive manufacturing
In FIGURE 1 a limited number of configurations and attachment means for
attaching, the first
set 102, the second set 104, and the fitting liner 105 are shown. However,
other configurations
and attachment means can be used in the design as well without departing from
the spirit and
scope of the invention. All the shown configurations and attachment means in
FIGURE 1 are not
necessarily needed to be in one design. A design can use one type or more of
the
configurations, features, or attachment means shown in FIGURE 1.
In an embodiment according to FIGURE 1, the deformation of the first set 102
and the second
set 104 and the relative movement of the fitting liner 105 and the second set
104 with respect to
the first set 102 enhance the helmet 101 performance and reduce the linear and
rotational
forces applied to the head 100 during an impact.
In an embodiment according to FIGURE 1, the fitting liner 105 covers multiple
parts of the
second set 104.
In an embodiment according to FIGURE 1, the anchor 108 attaches the first set
102 to the
second set 104, and the fitting liner 105 by means of the connector 121 and
the button 114
through the opening 126 in the second set 104 and a buttonhole in the fitting
liner 105 (not
shown in FIGURE 1). The connector 121 can be elastic to elongate when the
applied force
exceeds a certain limit or it can be rigid and have minimal elongation under
the force. The
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anchor 108 can be in form of a snap pin and snap pin basket, and the connector
121 can
include a hole to attach to the first set 102 by means of the snap pin and
snap pin basket.
According to the previous embodiment of FIGURE 1, during an impact, parts of
the second set
104 can each move separately relative to the first set 102 based on the
location, direction, and
intensity of the impact. The movement of the parts of the second set 104
relative to the first set
102 improves the helmet performance in reducing both linear and rotational
forces.
In an embodiment according to FIGURE 1, the button 114 is a continuation of
the connector
121.
In an embodiment according to FIGURE 1, using the second set 104 in
conjunction with the first
set 102 allows for designing helmets with reduced overall raw material used
for the shock-
absorbing liner of the helmet 101 and reduces the weight of the helmet 101.
In an embodiment according to FIGURE 1, each part of the second set 104
consists of subparts
that are attached to each other by a rigid or flexible attachment means.
Using the second set 104 reduces some of the limitations in designing such as
convergence. In
moulding, to be able to release a rigid moulded object there should be a draft
angle meaning the
facing walls should diverge in the direction that a mould opens Otherwise, if
the facing walls
converge the mould cannot release the moulded object (e.g. helmet). In an
embodiment
according to FIGURE 1, it is possible to allow wall 122 and wall 123 to
converge, as the parts of
the second set 104 are made separately and then assembled. Having no
convergence limitation
opens up many different possibilities for designing high-performing shock-
absorbing liners for
helmets.
In an embodiment according to FIGURE 1, certain shapes are defined for the
second set 104 to
match the curvature of the inward surface of the first set 102 that is facing
the wearer's head
100.
In an embodiment according to FIGURE 1, the surface of the first set 102 that
faces the second
set 104 is designed to facilitate the movement of the parts of the second set
104 relative to the
first set 102.
In an embodiment according to FIGURE 1, the surface of the second set 104 that
faces the first
set 102 is designed to facilitate the movement of the parts of the second set
104 relative to the
first set 102.
In an embodiment, one or more shapes and sizes are used repeatedly for all the
required parts
for the second set 104 of the helmet 101. By using one or more similar parts
for all the required
parts for the second set 104, it is possible to reduce the cost of
manufacturing.
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In an embodiment according to FIGURE 1, universal shapes are designed for all
the parts of the
second set 104. The universal shapes can be used for some or all the required
parts of the
second set 104 of an array of different helmets. For helmets with various
shapes and
curvatures, the design of the inward surface of the first set 102 that faces
the wearer's head 100
can be modified accordingly to allow one or more universal shapes to be used
for the parts of
the second set 104 and the corresponding fitting liner 105 of different helmet
models. This is a
cost-effective method for adopting this invention for various existing or new
helmet models and
types. By changing the moulding tool of the helmet and creating the needed
surface for the
inward surface of the first set 102 of the helmet 101, it is possible to use
the universal shapes
for some or all the parts of the second set 104. The embodiment can be
arranged to be used for
different helmets of the same or different sizes. For instance, if the
universal shapes for the
parts of the second set 104 are defined for the size medium bicycle helmet.
Then, by modifying
the inward surface of the first set 102 of other helmet designs, it is
possible to use the same
universal shapes for the parts of the second set 104 for different bicycle
helmet designs that
have a size medium.
In an embodiment according to FIGURE 1, the first set 102 includes the
protrusion 124 and the
second set 104 includes the indentation 125 (open-cavity) that is used for
fitting or press-fitting
the second set 104 with or without the attachment means to the first set 102.
The fitting can also
be done by an indentation in the first set 102 instead of protrusion 124 and
protrusion in the
second set 104 (not shown in FIGURE 1).
In an embodiment according to FIGURE 1, the outward surface of the first set
102 that is facing
away from the wearer's head 100 is considered as the outer shell 103.
In an embodiment according to FIGURE 1, the second set 104 can include
sensors, electronics,
batteries, communication devices, and wiring. For example, an impact-sensing
device can be
included in the second set 104 to detect, record, or send a signal about a
crash incident.
In an embodiment according to FIGURE 1, the second set 104 is detachable and
can be
replaced when needed and allowed by the standard body.
In one embodiment according to FIGURE 1, the connector 121 is elastic and
elongates and
results in temporary or permanent dislocation of the second set 104 when the
applied force to it
exceeds a certain limit. For instance, silicone rubber can be used for the
connector 121.
In one embodiment according to FIGURE 1, the surface of the second set 104
that faces the
first set 102 has the recess 127 to not obstruct the finite movement of the
second set 104
relative to the first set 102 when the connector 121 is present. The recess
127 can be in any
size, shape, or direction. For example, the open cavity 120 can be where the
opening 126 of the
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connector 121 faces the first set 102 to facilitate the movement and
dislocation of the second
set 104 when the applied force to the helmet exceeds a certain limit.
In one embodiment, the opening 126 is an all-the-way-through hole or groove in
the second set
104 that allows the first set 102, the second set 104, and the fitting liner
105 to attach to each
other by means of anchor 108, the connector 121, buttonhole in the fitting
liner 105 (not shown
in FIGURE 1), and the button 114.
In one embodiment, the opening 126 is an all-the-way-through hole or groove in
the layer 118,
the second set 104, and the layer 117 to allow the first set 102, the second
set 104, and the
fitting liner 105 to attach to each other by means of anchor 108, the
connector 121, buttonhole
in the fitting liner 105 (not shown in FIGURE 1), and the button 114.
In one embodiment according to FIGURE 1, the surface of the second set 104
where it faces
away from the wearer's head 100 comprises the recess 127 where it faces the
anchor 108. The
recess 127 does not allow the attachment means such as anchor 108 or the
connector 121 to
obstruct the finite movement of the second set 104 relative to the first set
102 when the applied
force to the helmet 101 exceeds a certain limit.
In one embodiment according to FIGURE 1, the surface area of the second set
104 facing away
from the wearer's head 100 is smaller than the surface area of the first set
102 that is facing the
wearer's head. This is a geometric constraint to ensure that the second set
104 does not cover
the entire surface of the first set 102 that is facing the wearer's head
100.In one embodiment
according to FIGURE 1, the surface of the first set 102 where the anchor 108
is placed and
where it faces the connector 121 comprises the recess 128. Having the recess
128 reduces the
chance of the attachment means such as anchor 108 or the connector 121 to
obstruct the finite
movement of the second set 104 relative to the first set 102 when the applied
force to the
helmet 101 exceeds a certain limit.
In one embodiment according to FIGURE 1, the recess 127 and the recess 128 are
facing each
other. Such an embodiment further helps the finite movement of the second set
104 relative to
the first set 102 in the presence of the connector 121.
In an embodiment according to FIGURE 1, the number and type of the attachment
means 106-
111 define whether or not the second set 104 can move relative to the first
set 102 during an
impact.
In an embodiment according to FIGURE 1, the number and type of the attachment
means 106-
111 define the type of movement (translational, rotational, or both) of the
second set 104
relative to the first set 102 during an impact.
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In an embodiment. the first set 102, the second set 104, and the fitting liner
105 are attached by
the connector 121 and the button 114. The connector 121 can elastically or
plastically elongate
when the applied force to the helmet exceeds a certain limit. The elongation
of the connector
121 allows the second set 104 to move relative to the first set 102. The
movement of the second
5 set 104 relative to the first set 102 and compression of the first set
102 and the second set 104
reduce the rotational and linear forces applied to the head 100 during impact.
In an
embodiment, the fitting liner 105 movement relative to the second set 104
reduces the rotational
forces applied to the head 100 during impact.
FIGURES 2-A, 2-B, and 2-C disclose multiple embodiments of the invention and
show a helmet
10 in various views. FIGURE 2-A shows the side view of the helmet 201
comprising the vent 206,
outer shell 210, and the chin strap hole 209.
FIGURE 2-B shows the bottom view of the helmet shown in FIGURE 2-A. According
to FIGURE
2-B, the helmet 201 comprises the outer shell 210, the first set 202, the
second set 203, the
fitting liner 204, and the attachment means 205. In an embodiment, the second
set 203 can
15 have an extension 208. The second set extension 208 can further enhance
the protection of the
helmet by protecting the wearer's head from impacting certain surfaces such as
sharp and
wedge-shaped surfaces.
In an embodiment according to FIGURES 2-A to 2-C, the second set extension 208
surfaces
facing the wearer's head can be lower than the rest of the second set 203 and
have no contact
20 with the fitting liner 204 or wearer's head during normal use and the
absence of an impact. The
attachment means 205 passes through an opening in the fitting liner 205 and an
opening in the
second set 203 and attaches to the first set 202.
In an embodiment according to FIGURES 2-A to 2-C, the attachment means 205
eliminates the
need of using other types of fasteners such as the hook-and-loop fastener to
attach the fitting
liner to the second set 203.
In an embodiment according to FIGURES 2-A to 2-C, one end of the attachment
means 205 is
like a button, and there is a buttonhole in the fitting liner 204 to hold the
fitting liner 204 in place.
The other end of the attachment means 205 comprises multiple holes and by
using a snap-pin
and an embedded snap-pin basket in the first set 202, the attachment means 205
attaches the
fitting liner 204 and the second set 203 to the first set 202. The thickness
of the second set 203
may vary in various locations, therefore, the multiple holes in the other end
of the attachment
means 205 allows the attachment means 205 to use the suitable hole for the
snap-pin and the
snap-pin basket to provide the required tightness for the attachment means 205
during
assembling the helmet 201.
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In an embodiment according to FIGURES 2-A to 2-C, the attachment means 205 is
made of
rubber, metal spring, plastic spring, fabric, elastics, silicone rubber, or a
combination thereof or
any other materials that stretch under the force and return to their original
length after being
stretched.
FIGURE 2-C shows the cross-section of the helmet shown in FIGURE 2-A, and 2-B.
According
to FIGURE 2-C, the helmet 201 comprises the first set 202, the second set 203,
the fitting liner
204, the attachment means 205, and the outer shell 206. In an embodiment
according to
FIGURE 2-C, the portion 207 of the attachment means 205 is embedded in the
first set 202. An
example of the portion 207 can be found in a design that includes a snap pin
and an embedded
snap pin basket as the portion 207 in the first set 202 to attach the fitting
liner 204, and the
second set 203 to the first set 202.
In one embodiment according to FIGURES 2-A to 2-C, the attachment means 205 is
made of an
elastic such as silicone rubber and is slightly stretched (preloaded) during
assembling the
helmet parts which allows the fitting liner 204 and the second set 203 to
attach to the first set
202. When the helmet is impacted the attachment means 205 elongates further to
allow the
second set 203 and the fitting liner 204 to move relative to the first set 202
The movement of
the second set 203 and the fitting liner 204 reduces the rotational and linear
forces applied to
the head during impact.
In an embodiment according to FIGURES 2-A to 2-C, the first set 202, the
second set 203, and
the fitting liner 204 are attached by the attachment means 205 that can
elastically or plastically
elongate when the applied force to the helmet exceeds a certain limit. The
elongation of the
attachment means 205 allows the second set 203 to move relative to the first
set 202. The
movement of the second set 203 relative to the first set 202 and compression
of the first set 202
and the second set 203 reduce the rotational and linear forces applied to the
head during
impact. In an embodiment, the fitting liner 204 movement relative to the
second set 203 reduces
the rotational forces applied to the head during impact as well.
In an embodiment according to FIGURES 2-A to 2-C, the surface area of the
second set 203
facing away from the wearer's head is smaller than the surface area of the
first set 202 that is
facing the wearer's head. This is a geometric constraint to ensure that the
second set 203 does
not cover the entire surface of the first set 202 that is facing the wearer's
head.
FIGURES 3A to 3C show an exploded view of a helmet according to a number of
embodiments
comprising the outer shell 301, the first set 302, the second set 303, the
fitting liner 304, and
attachment means 305. FIGURE 3-A shows the first set 302 and in an embodiment,
it
comprises the outer shell 301 and air vents 306. FIGURE 3-B shows the second
set 303 and
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the fitting liner 304. In an embodiment according to FIGURE 3-B, the second
set 303 comprises
open cavities 308, the open cavities 308 can enhance shock absorption of the
helmet and also
reduce the weight of the second set 303. The open cavity 308 can be in any
shape, size, and
form. In an embodiment according to FIGURE 3-B, the second set 303 has the
extension 3011
to better protect the head for areas between two or more second sets 303. The
extension 311
can have a lower thickness than the adjacent parts of the second set 303. The
extension can be
covered or not covered by the fitting liner 304.
In an embodiment according to FIGURES 3-A and 3-B, the second set 303 is
covered by the
layer 309 where it comes into contact with the first set 302. The layer 309
can reinforce and
strengthen the structure of the second set 303 and also control and reduce the
friction between
the second set 303 and the first set 302. For example for helmets made of EPS,
the layer 309
can be made of a thin layer of polycarbonate.
In an embodiment according to FIGURE 3-B, the layer 309 covers the surface
area of the
second set 303 where it comes into contact with the fitting liner 304.
In an embodiment according to FIGURE 3-B, the existence of the layer 309
further enhances
the helmet performance in terms of reducing linear and rotational forces
In one embodiment according to FIGURES 3-A to 3-C, there is a through-hole 310
which allows
the attachment means 305 to pass through the second set 303 and attach the
fitting liner 304
and the second set 303 to the first set 302. In one embodiment according to
FIGURE 3-B, there
is a recess 307 adjacent to the hole 310. The recess 307 reduces the chance of
the attachment
means 305 to be snagged by the second set 303 during its movement due to
impact and hence
it facilitates the movement of the second set 303 and the fitting liner
relative to the first set 302.
In an embodiment according to FIGURE 3-A to 3-C, sensors, electronics,
batteries, impact alert
system, and positioning system can be placed in the open cavities 308.
In an embodiment according to FIGURE 3-C, the attachment means 305 are used to
attach the
fitting liner 304 and the second set 303 to the first set 302. In an
embodiment according to
FIGURE 3-C, the attachment means 305 at one end has a button-shaped, and at
the other end
has multiple holes which makes it adjustable, and therefore, suitable for
various thicknesses of
the second set 303.
In an embodiment according to FIGURE 3-C, one end of the attachment means 305
is button-
shaped and by having a button-hole on the fitting liner 304, the attachment
means 305 attaches
the fitting liner 304 and the second set 303 to the first set 302.
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In one embodiment according to FIGURE 3-A to 3-C, the attachment means also
includes snap-
pins and snap-pin baskets to attach the other end of the attachment means 305
to the first set
302. The snap-pin basket can be embedded in the first set 302 during its
moulding.
FIGURES 4-A to 4-C show the cross-section view of FIGURES 3-A to 3-C,
respectively.
FIGURE 4-A shows the cross-section of the first set 402. In an embodiment
according to
FIGURE 4-A, the first set 402 comprises the outer shell 401 and air vents 406.
In one
embodiment, parts 412 or 413 of the attachment means 405 are embedded in the
first set 402.
The depth that parts 412 and 413 can vary depending on the thickness of the
first set 402 where
the parts 412 and 413 are embedded in the first set 402 and the thickness of
the second set 403
where the hole 411 (hole 411 also represents the buttonhole in the fitting
liner) is facing the
parts 412 and 413. For example, the parts 412 and 413 can be snap-pin and snap-
pin baskets
to attach one end of the attachment means 405 to the first set 402. FIGURE 4-B
shows the
cross-section of the second set 403. In an embodiment according to Figure 4-B,
the second set
403 comprises the layer 408, the recess 407, and extension 411.
In an embodiment according to Figure 4-B, the fitting liner 404 comprises a
recess 414 and also
the buttonhole 411 The button-hole 411 is used for attaching the fitting liner
404, and the
second set 403 to the first set 402 by the attachment means 405 to the parts
412 and 413 of the
first set 402.
FIGURE 4-C shows the cross-section of FIGURE 3-C. The attachment means 405 and
parts
412 and 413 are used to attach the fitting liner 404 and second set 403 to the
first set 402.
In an embodiment, the surface area of the second set 403 facing away from the
wearer's head
is smaller than the surface area of the first set 402 that is facing the
wearer's head. This is a
geometric constraint to ensure that the second set 403 does not cover the
entire surface of the
first set 402.
FIGURES 2-A to 2-C, FIGURES 3-A to 3-C and FIGURES 4-A to 40 show only
examples of
using features, aspects and embodiments explained in the rest of this
invention. All the
embodiments, features, and aspects explained for FIGURE 1 regarding the first
set, the second
set, the fitting liner, and the attachment means, where applicable, can be
considered for the
examples provided in FIGURES 2-A to 2-C, FIGURES 3-A to 3-C and FIGURES 4-A to
40.
While illustrative embodiments have been illustrated and described, it will be
appreciated that
various changes can be made. The detailed description set out above in
connection with the
included sketches, where like numerals reference like elements, is intended as
a description of
various embodiments of the claimed subject matter and is not intended to
represent the only
embodiments. Any reference to a direction is specific only to the diagram, to
further clarify the
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explanation, not to limit the actual use of the invention in that direction.
The intention for the
illustrated examples is not to be exhaustive or to limit the invention to the
precise forms shown.
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