Mold for the manufacture of sporting helmets and relative process for molding such sporting helmets

A mold and a relative molding process for the manufacture of sporting helmets, in particular cycling helmets. The mold includes a frame provided with at least one molding concavity; a counter frame engageable to the frame to hermetically close the respective molding concavity and allow the execution of at least one molding cycle. The mold further includes at least one intermediate support element for supporting and positioning one or more components of the sporting helmet to be manufactured inside the respective molding concavity of the frame. The intermediate support element is kept inside the respective molding concavity during the entire molding cycle in order to keep the components of the sporting helmet to be manufactured in their assigned positions.

BACKGROUND OF THE INVENTION

The present invention relates to a mold for the manufacture of sporting helmets, in particular cycling helmets.

The present invention also relates to a process for molding the aforementioned sporting helmets and, in particular, the relative cycling helmets.

DESCRIPTION OF THE RELATED ART

The present invention is directed to the sector of production of sporting helmets and, in particular, cycling helmets.

As is known, cycling helmets are manufactured using suitable molds, each being provided with a female half-mold and a male half-mold.

Each mold is provided with respective supply channels for the polystyrene to be injected for the formation of the helmet, as well as with a plurality of holes for supplying the steam necessary for carrying out the molding cycle.

During the molding cycle, the polystyrene, in the form of spheres, undergoes a process of softening and expansion inside the mold cavity so that it takes on the shape of the product to be manufactured, i.e. the base body of the helmet designed to absorb shocks.

Once the base body has been obtained, it is removed from the mold to allow an operator to assemble further components of the helmet, such as the upper shell, the lower ring or under shell and any other components that need to be joined to the base body.

The base body, together with the additional helmet components, is inserted back into the mold in order to be subjected to a second molding cycle aimed at definitively binding the additional components to the base body.

Once the second molding cycle has been completed, the helmet obtained is removed from the mold again in order to be subjected to the final finishing operations, application of the padding and quality control.

In an attempt to improve the above-described molding process by making it quicker and more precise with obvious improvements in terms of the quality of the products obtained, the Applicant has designed and developed a support template which allows the positioning of the additional components of the sporting helmets to be manufactured inside the relative molds according to predetermined positions which must be maintained during the molding cycle.

The use of the above mentioned support template allows one of the two molding steps of the traditional molding process to be eliminated, ensuring a high percentage of repeatability of the precise positioning of the additional components inside the molds.

The support template and the relative process for molding by means of such a support template are described in detail in Italian Patent No. 102018000007587.

Although the aforementioned support template and the relative molding process allow for a considerable improvement of the traditional molding technique for sporting helmets, the Applicant has found that they are not free of certain drawbacks and are improvable in several respects, mainly in relation to the overall production times and to the elimination or maximum reduction of imperfections in the obtained sporting helmets.

In particular, the Applicant has found that the molding process by means of a support template referred to in Italian patent no. 102018000007587 comprises an operating step which presents some criticalities that can be found both in relation to production times and in relation to some imperfections present on the sporting helmets obtained, as well as to the risk of damage to the molds.

The Applicant has in fact been able to note that after having positioned all the additional components on a support template according to the relative predetermined positions, this support template is first inserted into the relative female half-mold in order to position the additional supported components in the relative molding positions where they are locked by corresponding locking mechanisms, to be subsequently removed and thus allow the closing of the mold and the start of the relative molding cycle.

In addition to lengthening the molding times of each molding cycle with undesirable repercussions on overall production times, the step of removing the support template from the relative female half-mold can in some cases result in imperceptible displacements of one or more additional components from their corresponding pre-set positions. In the best of cases, this unexpected event can lead to the onset of minor defects in the obtained sporting helmets. In the worst cases, the displacement of an additional component can also result in the damage to a mold when the latter is closed to start the molding cycle.

BRIEF SUMMARY OF THE INVENTION

The main object of the present invention is to propose a mold for the manufacture of sporting helmets, in particular cycling helmets, and a relative molding process capable of solving the problems encountered in the prior art.

It is an object of the present invention to further speed up the process for molding sporting and cycling helmets in such a way as to further reduce the overall production times of such helmets.

It is also an object of the present invention to ensure that high quality sporting and cycling helmets are obtained.

It is also an object of the present invention to ensure the structural integrity of the molds for the manufacture of the above-mentioned sporting and cycling helmets.

The above specified and yet further purposes are substantially achieved by a mold for the manufacture of sporting helmets, in particular cycling helmets, and a relative process for molding such sporting helmets, as described and claimed in the following claims.

By way of example, the description of a preferred but not exclusive embodiment of a mold for the manufacture of sporting helmets, in particular cycling helmets, and of a relative process for molding such sporting and cycling helmets is now disclosed, in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

With reference to the appended figures, three components of a mold for the manufacture of sporting helmets, in particular cycling helmets, in accordance with the present invention are shown separately or in pairs.

As visible inFIGS.1and2, the mold comprises at least one frame1which defines at least or one molding concavity2, preferably two or more molding concavities2, for molding at least one respective sporting helmet A (FIGS.9and10).

Advantageously, the presence of two or more molding concavities2per each mold allows the simultaneous manufacture of two or more sporting helmets A with a considerable increase in the number of sporting helmets A produced.

With reference toFIG.8, the mold also comprises a counter frame3for each molding concavity2engageable to the frame1to hermetically close the respective molding concavity2and allow the execution of at least one molding cycle for the manufacture of a corresponding sporting helmet A.

With reference toFIGS.1and3to10, the mold further comprises, for each molding concavity2provided in the frame1, at least one intermediate support element4for supporting and positioning one or more components B, for example made of polycarbonate or another similar material, of the sporting helmet A to be made, inside the respective molding concavity2of the frame1.

In detail, each intermediate support element4has a first portion5arranged to receive in engagement one or more components B of the sporting helmet A to be manufactured according to respective predetermined positions and a second portion6, facing away from the first portion5, having at least one grip handle7, preferably two opposite grip handles7, for manual positioning of the intermediate support element4in the respective molding concavity2of the frame1and the consequent positioning of the components B of the sporting helmet A to be manufactured inside said molding concavity2.

As can be seen inFIG.1, in order to allow an optimal closure of each molding concavity2of the mold frame1from the respective counter frame3, each intermediate support element4is advantageously arranged to perfectly couple with the respective counter frame3, in correspondence with the second portion6. In this way, when each counter frame3hermetically closes the corresponding molding concavity2of the frame1of the mold, it also abuts against the respective intermediate support element4present inside said molding concavity2to maintain the components B of the sporting helmet A to be manufactured in the predetermined positions during the relative molding cycle.

As can be seen inFIGS.1,3to6and10, each intermediate support element4comprises a substantially annular structure8having internally at least one support seat9and/or a relief10of at least one component B of the sporting helmet A to be manufactured.

Again with reference to the figures inFIGS.1,3to6and10, the support seat9and/or the relief10are accessible from the first portion5of each intermediate support element4, so that the positioning of the aforementioned components B of the sporting helmet A is carried out by keeping the first portion5of each intermediate support element4facing upwards or towards the Figure of the operator who is carrying out the action of positioning these components B of the sporting helmet A to be manufactured.

Preferably, the positioning of the components B of the sporting helmet A to be manufactured is performed by resting the second portion6of each intermediate support element4on a work plane or similar support plane in such a way that the first portion5of said intermediate support element4is easily reachable by the hands of the operator who has to position the components B of the sporting helmet A to be manufactured.

Again with reference toFIGS.1,4to7,9and10, the aforementioned grip handles7are defined by the annular structure8of the respective intermediate support element4.

In particular, each grip handle7comprises a gripping portion7adesigned to be manually gripped by an operator. The gripping portion7aof each grip handle7is defined by a block engaged to the annular structure8of the respective intermediate support element4, for example by means of corresponding threaded engagement elements7b.

Each grip handle7further comprises at least one gripping opening7cdefined between the annular structure8of the respective intermediate support element4and the corresponding gripping portion7ato allow insertion of the fingers of an operator's hand when he has to grasp the grip handle7.

Advantageously, the mold comprises at least one engagement member11for the stable coupling of each intermediate support element4to the frame1inside the respective molding concavity2.

In particular, the engagement member11is operatively interposed between each intermediate support member4and the respective molding concavity2of the frame1.

More and more particularly, the engagement member11comprises at least one locking seat11a(FIGS.3to12), preferably two opposite locking seats11a, realized outside the annular structure8of each intermediate support element4.

The engagement member11further comprises at least one locking protuberance11b(FIGS.1,11and12), preferably two opposite locking protuberances11b, for each molding concavity2of the frame1. Each pair of locking protuberances2of each molding concavity2is movable within the respective molding concavity2of the frame1between a rest position (FIGS.1and11) wherein the respective intermediate support element4can be inserted into the corresponding molding concavity2or removed therefrom and a locking position (FIG.12) wherein said locking protuberances11bengage the respective locking seats11aof the respective intermediate support element4, holding the latter inside the respective concavity molding2of frame1.

As can be seen inFIGS.1,11and12, the locking protuberances11bof each molding concavity2are operationally located in correspondence with peripheral areas of the respective molding concavity2, whereby the movement of these locking protuberances11bfrom the rest position to the locking position causes a displacement of the same towards the central part of the respective molding concavity2, that is towards one another. On the contrary, when the locking protuberances11bof each molding concavity2are moved from the locking position to the unlocking position, they move away from the central part of the respective molding concavity2, moving away from each other.

Advantageously, the locking protuberances11bof each molding concavity2can be controlled by means of an actuation device (not visible in the attached figures) located outside the mold. Preferably, the actuation device of the locking protuberances11bof each molding concavity2comprises at least one drive pedal. Even more preferably, the actuation device may comprise two or more drive pedals for the independent control of each pair of locking protuberances11bof each molding concavity2or jointly control of all the locking protuberances11bof the molding concavities2of the mold frame1.

As can be seen inFIGS.11and12, the actuation device of the locking protuberances11bof each molding concavity2of the mold frame1, activates these locking protuberances11bby means of corresponding fluid-dynamic actuators11c(FIGS.2,11and12) operationally located on the mold frame1.

Advantageously, the mold comprises at least one engagement constraint12(FIGS.1and3to12) for the stable coupling of each intermediate support member4to the corresponding counter frame3. Each engagement constraint12is operationally interposed between the respective intermediate support element4and the counter frame3.

In detail, each engagement constraint12comprises at least one coupling lug12a, preferably two opposite coupling lugs12a, and at least one coupling seat12b, preferably two opposite coupling seats12b, operatively interposed between the respective intermediate support element4and the corresponding counter frame3.

Preferably, each coupling lug12aof each engagement constraint12protrudes externally from the annular structure8of the respective intermediate support element4and each coupling seat12bof each engagement constraint12is realized on the respective counter frame3.

Preferably, each coupling lug12aand the respective coupling seat12bof each engagement constraint12are at least partly countershaped to ensure a stable coupling between the respective intermediate support element4and the corresponding counter frame3.

According to a preferred aspect of the present invention, each locking seat11aof the locking member11is externally realized on a respective coupling lug12aof a respective engagement constraint12.

Advantageously, the mold further comprises, for each molding concavity2of the frame1, at least one auxiliary support element identical to the respective intermediate support element4. Each auxiliary support element is usable to prepare one or more components B of a sporting helmet A which still has to be manufactured while the respective intermediate support element4is engaged in the respective molding concavity2during a respective molding cycle of the mold.

In other words, while each intermediate support element occupies the respective molding concavity2during the relative molding cycle of the corresponding sporting helmet A, each auxiliary support element is set up and prepared with respective components B of the sporting helmet to be manufactured subsequently, to be inserted into the respective molding concavity2as soon as the latter is freed from the corresponding intermediate support element4.

The present invention also relates to a process for molding sporting helmets A, in particular cycling helmets, which will be described below.

The molding process comprises a step of providing the above-described frame1of the mold with the respective molding concavities2for molding the respective sporting helmets A and a step of preparing the respective counter frames3of the same mold designed to hermetically close the respective molding concavities2and allow the execution of the respective molding cycles.

The process further comprises a step of preparing the respective intermediate support elements4of the mold for supporting and positioning the components B of the sporting helmets A to be manufactured inside the respective molding concavities2of the frame1of the mold.

Following the provision of the frame1, the respective counter frames3and the respective intermediate support elements4, the molding process comprises a step of placing one or more components B of the sporting helmets A to be manufactured in the first portion5of each intermediate support element4(FIGS.5and6) according to respective predetermined positions.

In detail, this step of placing is performed by accessing a series of seats9and/or reliefs10inside the annular structure8of each intermediate support element4through the respective first portion5thereof.

In order to be able to easily access the first portion5of each intermediate support element4and fix the components B of the respective sporting helmets A to be manufactured in correspondence with the respective support seats9and/or reliefs10, said first portion5is to be kept facing upwards or towards the Figure of the operator who is carrying out the action of placing the components B.

More specifically, the placing of the components B of the sporting helmets A to be manufactured is carried out by resting the second portion6of each intermediate support element4on a work plane or a similar support plane in such a way that the first portion5of this intermediate support element4is easily reachable by the hands of the operator who has to position the components B of the sporting helmet A to be made in the corresponding support seats9and/or on the corresponding support reliefs10of these intermediate support elements4.

Once the step of placing the components B of the sporting helmets A to be manufactured in the corresponding support seats9and/or on the corresponding support reliefs10of the respective intermediate support elements4is completed, the molding process comprises the step of positioning each intermediate support element4inside the corresponding molding concavity2of the mold frame1(FIG.7).

This step is performed by first orienting the first portion5of each intermediate support element4towards the respective molding concavity2, then inserting said intermediate support element4into the respective molding concavity2in such a way as to place the components B of the respective sporting helmet A to be manufactured inside the latter according to corresponding predetermined positions.

The step of positioning each intermediate support element4in the respective molding concavity2with the respective components B of the corresponding sporting helmet A to be manufactured is performed manually by an operator, preferably by grasping the gripping portion7aof each grip handle7defined in correspondence with the second portion6of each intermediate support element4.

Preferably, the step of positioning each intermediate support element4in the respective molding concavity2is performed by inserting this intermediate support element4in the corresponding molding concavity2along a direction substantially orthogonal with respect to a main lying plane X (FIGS.1and2) of the frame1of the mold.

When each intermediate support element4is positioned inside the corresponding molding concavity2, each intermediate support element4is locked in the respective molding concavity2to avoid unwanted displacements and fix the predetermined position for the components B of the respective sporting helmet A to be manufactured.

As can be seen inFIG.12, the step of locking each intermediate support element4in the respective molding concavity2of the frame1of the mold is carried out by the interaction between the movable locking protuberances11binside the respective concavity2and the respective locking seats11arealized externally on the respective intermediate support element4.

The step of locking each intermediate support element4in the respective molding concavity2of the frame1of the mold is carried out by activating the respective locking protuberances11bfrom the rest position (FIGS.1and11) wherein the respective intermediate support element4can be inserted into the corresponding molding concavity2or removed therefrom to the locking position (FIG.12) wherein the respective locking protuberances11bengage the respective locking seats11aof the corresponding intermediate support element4, holding the latter inside the respective molding concavity2of the mold frame1.

The locking step is advantageously carried out by movement operating the locking protuberance11bby operating a control device located externally to the mold, preferably at least one control pedal.

The locking of each intermediate support element4in the respective molding concavity2can be activated independently by operating a respective dedicated control pedal or simultaneously on all the molding concavities2of the frame1of the mold by means of a suitable general control pedal.

Once the locking is finished, the molding process provides for the subsequent step of engaging each counter frame3of the mold to the frame1thereof in order to hermetically close the respective molding concavity2at the second portion6of the respective intermediate support element4facing outwards from the respective molding concavity2.

The step of engaging each counter frame3of the mold to the frame1thereof is also carried out by engaging the aforementioned coupling lugs12awhich protrude externally from each intermediate support element4in the respective coupling seats12brealized on the corresponding counter frames3of the mold.

Once each molding concavity2of the mold frame1has been closed, a respective known molding cycle is started by injecting a corresponding molding material, preferably polystyrene.

When the molding cycle has reached its end, the molding process comprises the subsequent step of disengaging each counter frame3of the mold from the frame1of the same in order to access the respective molding concavity3and the corresponding intermediate support element4contained therein.

The step of disengaging each counter frame3of the mold from the frame1of the same is also carried out by disengaging the respective coupling lugs12awhich protrude externally from the respective intermediate support elements4from the respective coupling seats12brealized on the respective counter frames3of the mold.

Each intermediate support element4is then released from the respective molding concavity2, again by the interaction between the respective locking protuberances11bthat are movable inside the corresponding molding concavity2and the respective locking seats11arealized externally on each intermediate support element4.

In particular, the unlocking step is carried out by movement operating the respective locking protuberances11bof each molding concavity2from the locking position (FIG.12) to the rest position (FIGS.1and11). In this way each intermediate support element is freed so that it can be removed from the respective molding concavity2.

Similarly to the locking step, the unlocking step is also carried out by operating at least one control device, preferably at least one drive and control pedal operatively connected to the respective locking protuberances11b.

Once each support element4has been released, it can be removed from the respective molding concavity2of the mold frame1together with the corresponding formed sporting helmet A (FIG.9).

The removal step is also carried out manually by an operator grasping the gripping portions7aof the corresponding grip handles7of the respective intermediate support element4defined at the second portion6of the latter.

The step of removing each intermediate support element4together with the respective sporting helmet manufactured by the respective molding concavity2is carried out by extracting said intermediate support element4along a direction substantially orthogonal to the main lying plane X of the mold frame1.

Subsequently, the molding process provides for a step of separating each intermediate support element4from the corresponding sporting helmet A manufactured (FIG.10), to allow the entire molding process to be repeated.

Advantageously, the above-described molding process may further comprise the use of an auxiliary support element (not illustrated in the attached figures) identical to the intermediate support element4for each molding concavity2of the mold frame1.

The auxiliary support element is advantageously set up with the components B of the sporting helmets A to be manufactured, while the corresponding intermediate support elements4are located inside the corresponding molding concavities2during a corresponding molding cycle.

When the intermediate support elements4are removed from the corresponding molding concavities2at the end of the molding cycle, the corresponding auxiliary support elements are immediately inserted into the corresponding molding concavities2to initiate a subsequent molding cycle, thus minimising the interruptions in the production cycle of sporting helmets A.

Since the auxiliary support elements are identical to the intermediate support elements4, the process steps that are carried out on the intermediate support elements4are also carried out in a similar manner on the auxiliary support elements. While the intermediate support elements4are arranged inside the respective molding concavities2of the mold frame1during a corresponding molding cycle, the operators prepare the auxiliary support elements with the corresponding components B of the sporting helmets to be manufactured. Conversely, when the auxiliary support elements4are arranged inside the respective molding concavities2of the mold frame1during a corresponding molding cycle, the operators prepare the auxiliary support elements with the corresponding components B of the sporting helmets to be manufactured.

The alternation of the intermediate support elements4with the auxiliary support elements ensures the continuity of the molding cycles of the sporting helmets being manufactured, thus considerably increasing the number of helmets produced in a unit of time.

The mold and the relative molding process described above solve the problems encountered with the prior arte and allow important advantages to be achieved.

In detail, the elimination of the step of removing the traditional support template before starting the molding cycle from the respective molding concavity has allowed, on the one hand, speeding up the molding process with significant reductions in the overall production times of the sporting helmets and, on the other hand, to ensure the maintenance of the positions of the components of the sporting helmets to be manufactured before the hermetic closure of the mold and during the execution of each molding cycle.

It should therefore be noted that keeping the intermediate support elements in the respective molding concavities of the mold frame allows an overall reduction of the process for molding each sporting helmet being manufactured.

In addition, keeping the intermediate support elements in the respective molding concavities of the mold frame ensures that the positions assigned to each component of the sporting helmet being manufactured are maintained before the mold is closed and throughout the entire molding cycle, so that the quality of the obtained sporting helmet is excellent and the mold is structurally preserved.