Modular molding systems and methods for making batting helmets

A system for manufacturing a shell for a batting helmet includes interchangeable mold-core portions configured to form a cavity for receiving molding material. The mold-core portions include a first base mold-core portion and a plurality of inner side mold-core portions configured to form an interior contour of the shell. The mold-core portions further include a second base mold-core portion and a plurality of outer mold-core portions configured to form an exterior contour of the shell. Mold-core portions are interchangeable, removable, and replaceable from an interlocked position relative to other mold-core portions. A method of manufacturing batting helmet shells includes selecting mold-core portions corresponding to various helmet shell configurations having various protective features, assembling the mold-core portions into a mold assembly, and providing molding material into a cavity in the mold assembly. A kit of parts for making a shell for a batting helmet includes a variety of interchangeable mold-core portions.

BACKGROUND

Helmets, such as batting helmets for baseball or softball, may include protection for a player's maxillary and mandibular regions (the cheek and jaw area) and for a player's orbital region (the eye area). Such protection may be in the form of a curved plate or shell attached to, and extending from, the main body of a helmet. Some helmets may be symmetric, such that the sides of the helmet are the same size and shape. Other helmets with cheek and jaw protection may be asymmetric (for example, asymmetric relative to a plane between a front part of the helmet and a rear part of the helmet). For example, cheek and jaw protection may only be provided on one side of the helmet. Many batters prefer symmetric helmets, but some batters prefer asymmetric helmets to account for their substantially perpendicular position relative to the incoming pitch. Asymmetrical helmets, however, may involve increased production costs.

SUMMARY

A system for manufacturing a shell for a batting helmet includes interchangeable mold-core portions configured to form a cavity for receiving molding material. The mold-core portions include a first base mold-core portion and a plurality of inner side mold-core portions configured to form an interior contour of the shell. The mold-core portions further include a second base mold-core portion and a plurality of outer mold-core portions configured to form an exterior contour of the shell. Mold-core portions are interchangeable, removable, and replaceable from an interlocked position relative to other mold-core portions. A method of manufacturing batting helmet shells includes selecting mold-core portions corresponding to various helmet shell configurations having various protective features, assembling the mold-core portions into a mold assembly, and providing molding material into a cavity in the mold assembly. A kit of parts for making a shell for a batting helmet includes a variety of interchangeable and interlockable mold-core portions.

Other features and advantages will appear hereinafter. The features described above can be used separately or together, or in various combinations of one or more of them.

DETAILED DESCRIPTION

The present technology is directed to modular molding systems and methods for making batting helmets. Various embodiments of the technology will now be described. The following description provides specific details for a thorough understanding and enabling description of these embodiments. One skilled in the art will understand, however, that the technology may be practiced without many of these details. Additionally, some well-known structures or functions, such as structures or functions common to batting helmets, plastic or polymer molding processes, or safety equipment in general, may not be shown or described in detail to avoid unnecessarily obscuring the relevant description of the various embodiments. Accordingly, embodiments of the present technology may include additional elements or exclude some of the elements described below with reference toFIGS. 1-7, which illustrate examples of the technology.

Where the context permits, singular or plural terms may also include the plural or singular term, respectively. Moreover, unless the word “or” is expressly limited to mean only a single item exclusive from the other items in a list of two or more items, then the use of “or” in such a list is to be interpreted as including (a) any single item in the list, (b) all of the items in the list, or (c) any combination of items in the list.

Specific details of several embodiments of the present technology are described herein with reference to baseball or softball. Embodiments of the present technology may be used in other protective equipment or in other sports or industries.

Turning now to the drawings,FIG. 1illustrates a front view of a batting helmet100according to an embodiment of the present technology.FIG. 2illustrates a side view of the batting helmet100, andFIG. 3illustrates a bottom view of the batting helmet100. The batting helmet100includes a rigid or semi-rigid shell110which may be partially or fully lined with a shock-absorbing material, which is not shown but is understood to those within the art. For example, the shock-absorbing material may include foam, gel, fabric, or other various forms of padding, liner(s), or other shock-absorbing material suitable for absorbing impact forces transmitted from the shell110. Comfort padding, or other comfort-providing material, may also be included inside the shell110.

The shell110may include a crown region120, a rear region130, a front (forehead) region140with or without an optional visor150, and side regions160. In general, the shell110may be configured to cover most or all of a player's head, with the exception of the player's face, which may generally be exposed or partially covered.

In some embodiments, the shell110may include one or more additional protective features, such as a jaw guard170. The jaw guard170may be configured (such as sized and shaped) to coextend with a user's mandible and maxilla, a user's cheek bones, a user's chin, or other anterior and lower portions of a user's face. The jaw guard170may protect a player's cheek, jaw, chin, or eye areas, or any suitable combination of cheek, jaw, chin, or eye areas. InFIGS. 1-3, the jaw guard170is illustrated as extending from the left side160of the shell110. Accordingly, the helmet100is an asymmetrical helmet, having jaw protection on one side160rather than both sides160. However, in other embodiments, the jaw guard170may be positioned on the right side160, on each side160, or neither side160. In other embodiments, other protective features, such as ear guards (extensions of the helmet100covering a user's ear), chin guards (extensions of the helmet100positioned to cover the front of a user's chin), or other protective shapes may be positioned on either side160or both sides160of the shell110.

Protective features may be positioned at various symmetrical and asymmetrical locations on the shell110. In some embodiments, protective features on opposing sides160may be the same size and shape as each other or they may have different sizes, shapes, or positions. For example, a right-handed batter may prefer a protective feature (such as a jaw guard or ear guard) on the left side of the helmet for increased protection from an incoming pitch, with reduced coverage on the right side to facilitate air flow, awareness of game play, and reduced overall helmet weight.

Embodiments of the present technology provide modular molding systems and methods to make any configuration of helmet100described herein, or other suitable configurations.

FIG. 4illustrates a modular molding system400in accordance with an embodiment of the present technology. The modular molding system400includes a plurality of mold-core portions configured and arranged to be brought together to form a cavity within which a molding material (such as plastic or polymer) may be received (such as injected or drawn in) to mold a helmet shell110.

For example, a lower base mold-core portion410and one or more (such as two) inner side mold-core portions420may, together, form a male core portion of a molding system. In other words, each of the lower base mold-core portion410and the inner side mold-core portions420may be shaped to form an interior contour of a shell110.

In some embodiments, the lower base mold-core portion410may include an inner front mold-core portion440, an inner crown mold-core portion430, and an inner rear mold-core portion450. The inner side mold-core portions420may be seated adjacent to the inner front mold-core portion440, the inner crown mold-core portion430, and the inner rear mold-core portion450. This seating may be accomplished, for example, by moving the inner side mold-core portions420along lines x1and x2, respectively, to position and engage protrusions475and inwardly-facing surfaces476of the inner side mold-core portions420in correspondingly-shaped slots or recesses460in the lower base mold-core portion410. In some embodiments, the inner side mold-core portions420may be positioned in the lower base mold-core portion410in other ways. The inner side mold-core portions420may be interchangeable (for example, removable and replaceable) with other inner side mold-core portions, and they may be interlocked with the lower base mold-core portion410and parts thereof.

An upper base mold-core portion470and one or more (such as three) outer mold-core portions480,490,492may, together, form a female core portion of a molding system. In other words, each of the upper base mold-core portion470and the outer mold-core portions480,490,492may be shaped to form an exterior contour of a shell110.

In some embodiments, the upper base mold-core portion470may be contoured to form the exterior contour of the front (forehead) region140(with or without an optional visor150) as shown inFIGS. 1-3. The rear outer mold-core portion480may be shaped to form the exterior contour of all or part of the rear region130of the shell110. Two outer side mold-core portions490,492may be shaped to form the exterior contour of all or part of the side regions160(with or without an optional jaw guard170or other protective features), as shown inFIGS. 1-3.

The outer mold-core portions480,490,492may be seated adjacent to, and spaced apart from, the inner side mold-core portions420and the inner crown male mold-core portion430(to form a cavity therebetween), for example, by moving the outer mold-core portions490,492,480along paths y1, y2, and y3, respectively, to position and seat the outer mold-core portions490,492,480in correspondingly shaped recesses495in the lower base mold-core portion410. In some embodiments, the outer mold-core portions480,490,492may include rails or grooves corresponding with rails or grooves in the lower base mold-core portion410to facilitate sliding the outer mold-core portions480,490,492into the lower base mold-core portion410along a track (such as with interlocking sliding rails). In other embodiments, the outer mold-core portions480,490,492may merely be positioned in a receiving recess495or otherwise seated in or on the lower base mold core portion410. The outer mold-core portions480,490,492may be interchangeable (for example, removable and replaceable) with other outer mold-core portions, and they may be interlocked with the upper base mold-core portion470and parts thereof, or with other mold-core portions.

When the mold-core portions (410,420,430,440,450,470,480,490,492) are brought together, a cavity in the shape of a shell110is positioned between adjacent core portions. For example, the lower base mold-core portion410and one or more other mold-core portions (such as portions420,430,440,450,480,490, or492) may be received in the upper base mold-core portion470(which may be configured to receive all or part of the lower base mold-core portion410or other mold-core portions). The inner side mold-core portions420may be received between the outer mold-core portions480,490,492. The cavity between the mold-core portions forming the exterior contour of the shell110and the mold-core portions forming the interior contour of the shell110may define a thickness of the shell110. The cavity is then filled with a polymer material, such as a plastic material or another suitable material to mold the shell110. For example, the cavity may be injected with material or material may be drawn into the cavity.

Although two inner side mold-core portions420and three outer mold-core portions480,490,492are illustrated and described, any suitable number of mold-core portions may be used to provide a shape of the shell110.

According to embodiments of the present technology, the quantity, arrangement, and shape of mold-core portions facilitate molding various shapes, sizes, and configurations of helmets in a single molding or tooling kit. For example, one, both, or neither of the inner side mold-core portions420and their corresponding adjacent outer side mold-core portions490,492may collectively form a cavity for protective features, such as a jaw guard170(seeFIGS. 1-3). In some embodiments, one, both, or neither of the inner side mold-core portions420and their corresponding adjacent outer side mold-core portions490,492may collectively form a cavity contoured to facilitate molding of other protective features, such as an ear guard, visor, or other helmet feature.

In some embodiments, one or more of the mold-core portions may be contoured to form protective features in the form of ribs extending along a side of the helmet (see ribs180illustrated inFIG. 3A). For example, the inner side mold-core portions420may include ribs496that provide corresponding ribs or contouring to the finished helmet. In some embodiments, one inner side mold-core portion420(left or right) may include ribs496, while the other may optionally not include ribs496. The outer side mold-core portions490,492may have corresponding ribs, depending on whether the corresponding inner side mold-core portions420have ribs496. A manufacturer or other user, therefore, may customize the inclusion or exclusion of ribs496on one or both sides of a helmet mold (and consequently, a helmet) depending on the desired helmet design. Ribs may provide enhanced protection by increasing impact attenuation (especially near the temporal lobe area of a user's head). A designer may optionally omit ribs from the side of a helmet facing away from the pitcher to reduce overall helmet weight. In some embodiments, there may be four ribs, some or all of which may be parallel to each other. In other embodiments, there may be more or fewer than four ribs, and the ribs need not be parallel in some embodiments (they may intersect each other). Ribs according to the present technology may be protrusions extending from the helmet100or indentations in the helmet100. Other protective features in the shell110(such as those described below with regard toFIGS. 6 and 7) may be formed in a similar manner.

Advantages of embodiments of the present technology include allowing a manufacturer or other user to use the same tooling kit or system to create various symmetric or asymmetric helmets (for example, with a jaw guard170or ribs180, or other protective features described herein, on one or both sides). The present technology provides reduced cost and complexity in manufacturing a variety of helmets. In addition, molding the jaw guard or other features integrally with the remainder of the helmet (as opposed to attaching them with fasteners or adhesive) improves the quality of the overall structure and eliminates the need for separate attachment elements, which improves safety for the end user. For example, in a molded helmet according to an embodiment of the present technology, impacts may be distributed along a larger surface area of the shell110rather than focusing the impact stress in a weak point, such as a fastened connection or other non-integral attachment. Likewise, an integrally formed helmet according to the present technology facilitates use of integrally-formed padding or liners for additional distribution of impact stresses. Because a helmet according to various embodiments of the present technology may include coverage extending from a user's ear, to a user's cheek, and potentially beyond to other areas of the head and face, such as wrapping around part of the user's mouth area, the total surface area covered by the helmet may be extensive compared to traditional helmets. A large continuous or mostly continuous pad or liner within the helmet may allow impact energy to be dispersed more evenly than several smaller protective pads or liners covering the same area.

Other embodiments allow designers to customize the shape, thickness, or other characteristics of the modular helmet mold in real-time during design, testing, and manufacturing efforts, without having to change entire sets of molding or tooling.

FIG. 5illustrates a flow diagram of a modular method500for making a helmet with a jaw protector or other protective features in accordance with an embodiment of the present technology. The method500may be carried out using, for example, a modular molding system configured in accordance with the present technology. In operation, beginning at block510, a manufacturer or other user selects the mold-core portions corresponding to a desired helmet configuration, such as a symmetric helmet (with two or no jaw guards or other symmetric features) or an asymmetric helmet (with a jaw guard or other features on only the left or right side, or differently configured features on either side).

At block520, the user assembles the selected mold-core portions into a complete helmet mold assembly formed by attaching or otherwise connecting the mold-core portions together. At block530, the user injects or draws molding material into the mold (such as plastic or another polymer or other material suitable for making helmets). At block540, the user allows the molding material to cure (as used herein, curing includes cooling of a previously-heated material or chemically curing as understood in the art of injection molding, for example) into its shape within the mold as a helmet shell. At block550, the user removes the shell from the mold, for example, by removing the mold-core portions to access the shell inside the cavity between mold-core portions. At block560, the user may attach other helmet components to the shell, such as padding, straps, or decorative indicia.

The method illustrated inFIG. 5may be repeated with other mold-core portions or other groups of mold-core portions. A user may replace one or more mold-core portions or groups of mold-core portions with different mold-core portions or different groups of mold-core portions to alter the shape of the resulting helmet shell. For example, a user may replace certain side mold-core portions having one or more features with different configurations of side mold-core portions having other features (such as replacing a side mold-core portion having a contour for a jaw guard with a side mold-core portion without a contour for a jaw guard).

FIG. 6illustrates a bottom perspective view of a batting helmet600according to another embodiment of the present technology. The helmet600may be generally similar to other helmets in accordance with the present technology, such as the helmet100illustrated inFIGS. 1-3A. In some embodiments, one or more of the mold-core portions (seeFIG. 4) may be contoured to form protective features in a finished helmet600in the form of dimples610arranged in various patterns, such as rows and columns, or other patterns. The dimples610provide alternative modes of force and impact distribution, which may be used in addition to or alternatively to other protective features (such as ribs180inFIG. 3A), and may be on one side, or multiple sides of a helmet600. A manufacturer or other user, therefore, may customize the inclusion or exclusion of protective features such as dimples610on one or more sides of a helmet mold (and consequently, a helmet600) depending on the desired helmet design. Dimples610according to the present technology may be protrusions (domes) extending from the helmet600or indentations in the helmet600.

FIG. 7illustrates a bottom perspective view of a batting helmet700according to another embodiment of the present technology. The helmet700may be generally similar to other helmets in accordance with the present technology, such as the helmet100illustrated inFIGS. 1-3Aor the helmet600illustrated inFIG. 6. In some embodiments, protective features may be in the form of a waffle or grid pattern710on one or more sides of a helmet700. The waffle or grid pattern710provides yet another alternative mode of force and impact distribution, and it may be used in addition to or alternative to other protective features (such as ribs180inFIG. 3Aor dimples610inFIG. 6). The waffle or grid pattern710may include one or more protrusions extending from the helmet700or indentations in the helmet700, or a mix of protrusions and indentations.

Other protective features molded into or onto shells110according to embodiments of the present technology include various shapes and patterns of indentations, protrusions, or groupings of indentations and protrusions, such as circles (cylinders), triangles, rectangles, squares, other rectilinear shapes, irregular shapes, honeycomb patterns, irregular patterns, or other shapes or patterns of protective features molded into one or more sides of helmet shells. Shapes and patterns of protective features need not be uniform and may vary (such as in size or pattern density) along the side region160or side regions160of helmets or they may be different on one side region160of a helmet than on another side region160of a helmet. Numerous variations of protective features are contemplated by embodiments of the present technology.

Embodiments according to the present technology provide modular systems and methods of creating a batting helmet. Such modular systems and methods may improve and economize manufacturing of batting helmets by facilitating custom molding options in the same molding system. For example, the same modular mold system may be used to mold helmets having various configurations and features. A user may select mold-core portions corresponding to the desired shell shape and substitute them for other mold-core portions within the molding system according to embodiments of the present technology.

From the foregoing, it will be appreciated that specific embodiments of the disclosed technology have been described for purposes of illustration, but that various modifications may be made without deviating from the technology, and elements of certain embodiments may be interchanged with those of other embodiments, and that some embodiments may omit some elements. For example, although some mold-core portions may be described and illustrated as upper or lower portions, in some embodiments, mold-core portions may be rearranged or configured in other ways, for example, such that the upper base mold-core portion is positioned beneath the lower base mold-core portion. In some embodiments, more or fewer mold-core portions may be used. For example, in some embodiments, the outer mold-core portions may be formed as two outer mold-core portions, such that one or both of the side outer mold-core portions (490,492) include some or all of the rear outer mold-core portion480. In some embodiments, the inner front mold-core portion, the inner rear mold-core portion, or the inner crown mold-core portion, or other mold-core portions in other embodiments, may be divided or separated into a plurality of discrete mold-core portions. Various embodiments of the technology may include helmets other than baseball or softball helmets, for other sports, activities, or industries.

Further, while advantages associated with certain embodiments of the disclosed technology have been described in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the technology. Accordingly, the disclosure and associated technology may encompass other embodiments not expressly shown or described herein, and the invention is not limited except as by the appended claims.