Headgear with securing structure for support straps

Headgear for bicycling and other activities comprises a hood comprising a porous, energy-absorbing molded plastics material with at least one strap for securing the hood to the head of a wearer, the strap being secured to a bow-shaped securing structure extending through an edge of the hood and partly embedded in material located between the inner and outer surfaces of the hood.

TECHNICAL FIELD 
The present invention relates to a headgear which is primarily intended for 
sports and recreation activities and which is designed to form or be able 
to form a safety helmet or the like. The headgear comprises a hood or 
similar which at least shows a frame and one or more support bands meant 
for support straps or similar which are intended to secure the headgear, 
hood or frame in a required position on a head of a person. It should 
perhaps be declared even at this beginning of the description of the 
invention that the frame referred to forms, or can form, the said hood, 
and provided with the support straps referred to forms, or can form, the 
said headgear. 
BACKGROUND 
The need exits for a new headgear which is able to form a safety helmet, be 
of low weight, and which is comfortable to wear, not least for children. 
An indispensable requirement in this respect is that a headgear of the 
type in question should remain in position on the head of the wearer in 
the event of an accident, blow, bump or the like, whereby it is of 
importance that the headgear can be adjusted to fit different personal 
sizes and shapes of head. Moreover, it is appreciated that the headgear is 
easy to put on and take off. Further, it is worth emphasizing that the 
headgear is really effective when used. A headgear of the type in question 
should be able to be produced at low cost so that it will be available for 
one and all. 
TECHNICAL PROBLEMS 
A known helmet or bicycle helmet primarily designed for children does not 
have inter alia attachment devices for support straps or the like. The 
support straps are thus arranged for the helmet by being threaded through 
ventilation openings arranged in the helmet or its hood. These ventilation 
openings are in the first place positioned in such a manner on the helmet 
or hood as to provide good ventilation, for which reason the positioning 
of the ventilation openings is not optimally adjusted for the attachment 
of the support straps and their running in the helmet, and at the same 
time the ventilation openings are not always positioned for effective 
ventilation. Besides, ventilation is obstructed by the support straps 
drawn through the ventilation openings. The running of the support straps 
is in this respect not of the best kind for the helmet to be maintained in 
an intended position in a reasonably manner, particularly not in the case 
of an accident and the like, where it is of critical importance that the 
helmet maintains its intended position on the head of the wearer. It is 
therefore easy for the helmet to be displaced from its intended position 
when for example bumps, sudden movements occurs, or when children are 
playing. It has proved to be the case that only a slight influence, such 
as a light bump or blow to or with the helmet, causes it to slip on the 
head out of position, which apart from missing the safety notwithstanding 
the use of a safety helmet implies the risk of a loss of vision if the 
helmet slips forwards and down over the face; the result of which can be 
disastrous for example in traffic, or for avoidance an accident or to 
mitigate the effects of an accident. The known helmet is therefore not 
effective when used and does not offer real protection. It is also the 
case that the helmet is made from a porous material, and one which is 
sensitive to abrasion, and therefore it is inappropriate to permit the 
support straps to run through the ventilation openings since these wear 
the material in the helmet or its hood and can damage the helmet, or at 
least undermine its strength. In addition, the ventilation openings are 
made after the helmet or hood has been manufactured, whereby the cut edges 
are especially porous. 
The basis for the above mentioned problems is constituted by inter alia the 
fact that the helmet or hood is made from expanded plastic material which 
results in a porous product. It would thus be an improvement for a frame, 
hood or helmet to be manufactured in a simple and rapid manner and at a 
low cost, and also be of low weight simultaneously that the material has a 
high energy absorbing capacity. The material in the helmet or hood, 
however, has far too inferior strength and is too porous to enable the 
arrangement of support straps and the like to the helmet or hood in the 
normal way, for example by riveting. Openings have therefore been made 
through the helmet or hood, or the ventilation openings have been 
utilized, for support devices. 
THE SOLUTION 
In the case of a headgear or safety helmet according to the present 
invention, however, the set requirements are met and the disadvantages of 
known helmets are eliminated. During development of the helmet a method 
has thus been created of arranging attachment points on the helmet, hood 
or frame for example support straps, chin bands and the like, and also for 
other devices. The attachment points can also be arranged at places where 
the attachment of for example support straps and the like is the best so 
that, according to the example, the headgear or the like will sit and 
remain in place on the head of the wearer in the required manner, and also 
with optimum safety, but also so that it will sit comfortably on the head. 
It is thus possible to achieve an appropriate running of the support 
straps and similar from and to the helmet and in contact with the wearer 
to ensure a comfortable and safe use of the headgear. In addition, the 
attachment points by virtue of worked out holders have strength and cannot 
come loose, be damaged or otherwise impaired, or impair the quality of the 
headgear, the hood or the frame, thus reducing the safety factor and 
reliability, without the headgear, hood or frame being totally destroyed. 
The support straps, chin bands and similar can be amply adjusted so that 
the intended position and comfort can be achieved and maintained during 
the use of the headgear, hood or frame which also has ample adjustment 
potential in order that it can be adjusted to and fit different sizes and 
head shapes. The ventilation openings in the headgear, hood or frame can 
be arranged at the most appropriate places for the ventilation and be 
shaped simultaneously and in the same manufacturing process as the hood or 
frame. Then there is the high density in the material which prevents that 
the sections limiting the ventilation openings ensures the strength. The 
headgear, hood or frame can also be manufactured in a simple and rapid 
manner and at a low cost, and from the favorable material which lend the 
headgear, hood and frame an extremely low weight and an almost negligible 
load on the person wearing the headgear. These conditions, together with 
the fact that the headgear is easy to wear, to put on and take off, and 
adjust, have the result that the headgear can be used by one and all as it 
is also well suited for children. There is therefore nothing to prevent 
all the members of a family, for example, from having their own helmet. 
The side surfaces of the headgear, hood or frame can be given a high 
density which ensures greater resistance to blow and abrasion, etc., and 
also an aesthetically attractive design. An aesthetically attractive 
design will contribute to that the helmet which by its very nature is a 
necessary precaution actually gets used. The headgear in accordance with 
the invention is thus characterized in that the frame is made of porous, 
energy absorbing and shape permanence material, and that the holders for 
support straps and similar are arranged in the frame and with a part of 
parts protruding from the frame, and that said support straps or similar 
are combined with the frame by attachment in said protruding parts of said 
holders. 
The invention also relates to a method to produce a headgear in accordance 
with the invention, whereby the headgear comprises a hood or similar and 
to the hood arranged or arrangeable support straps or similar, whereby the 
hood or a frame to the headgear or the hood is shaped by molding in a 
molding tool showing at least two mold halves. The method is characterized 
in that anchoring openings for holders or holders for connection of the 
support straps or similar to the headgear, the hood or the frame are 
arranged in the hood or the frame in connection with the molding of the 
hood or the frame in the molding tool, whereby in applicable cases said 
holders are placed in the molding tool before the molding of the hood or 
the frame and are molded into the hood or the frame and also brought with 
a part or parts to protrude from the hood or the frame.

BEST MODE FOR CARRYING OUT THE INVENTION 
The reference designations 1, 2 and 2' in FIGS. 1-4 and 13 show a headgear, 
hood or a frame or a headgear, hood and a frame respectively. The frame 2' 
is molded from expanded plastic material, such as expanded polystyrene, in 
a molding tool showing at least two mold halves. The frame actually 
constitutes the hood 2 to the headgear 1 or the actual headgear 1. 
According to one embodiment the holder 3 or the like is arranged in the 
frame 2' and in connection with the molding and manufacturing of the 
frame, the hood or the headgear, whereby the frame 2' with the arranged 
holders 3 can be said to form a part of the headgear 1 or a hood 2. When 
the frame 2' or the hood 2 is provided with support straps 6, 7, chin band 
8 or the like, the product constituted in this manner will form a headgear 
1 or a safety helmet. For the sake of simplicity the headgear 1 or the 
like will in the following description of the invention be designated as 
safety helmet or helmet. 
By molding the helmet from expanded plastic material a helmet is achieved 
with high energy absorbing and shock absorbing properties. When 
manufacturing in the manufacturing process one enables high density, thus 
ensuring compact material and above all a compact surface layer or compact 
surface layers for the helmet, the surface layer or layers of which are so 
compact that a subsequent machining or after-treatment to attain for 
example finish or the like is not necessary. Furthermore, helmets can be 
molded with varying decorations, patterns and the like, and also in 
different colors. The helmet can also be provided with decorations in the 
shape of decals 40 or the like. 
The holders 3 according to the embodiments are shaped as separate elements 
and made from plastic material which is relatively rigid and sufficiently 
rigid that an end section or end sections which will form protrusions 4, 
become rigid or stiff. At the same time, however, the holders 3 according 
to the embodiments shown in FIGS. 5-7 should be sufficiently flexible that 
they can be brought to an intended tensioning into the frame 2' during the 
manufacturing of the helmet. The holders 3 should also be made of a 
material with high strength. 
The holders 3 show a number of recesses or openings 13 which save material 
and weight but promote the attachment of the holders in the helmet, since 
the material can penetrate in and through the openings and anchor the 
holders. Furthermore, there are end trusses, flanges 14 or the like which 
divide the holder 3 in an attachment part 12 and the protruding part 4 or 
parts. The flange 14 or flanges are located in the helmet's lower 
peripheral edge 38 and limit the molding chamber in the molding tool, 
since they are located in the peripheral edge of the molding chamber. 
Engagement devices 17 are arranged in the parts 4, for example in the 
shape of holes for connection of the support straps 6, 7 or the like. 
According to one embodiment and when the helmet 1, the hood or the frame 2' 
will be manufactured one or more, for example two bow shaped holders 3 
each with two protruding parts 4 are arranged in the open molding tool, 
after which the molding tool is closed with at least two mold halves which 
guide or form the holders 3 to the correct cross sectional position in the 
mold chamber so that the holders will be molded in the middle of or 
between the surfaces of the helmet's or the like wall. This is done by the 
fact that the two mold halves touching position devices 15 shown by the 
holders 3 or touching contact surfaces 35 shown by the position devices. 
Position devices and contact surfaces are arranged and directed in 
opposite directions on the holders. This thus ensures that the holders 3 
becomes located in the middle of the material, see FIG. 3 and 4. The frame 
2' manufactured in this way with holders 3 forms in this case a hood 2 or 
a frame 2'. In order to further reinforce the attachment of the holders 3 
and particularly in connection with the protruding part 4, which should be 
located in the front section 31 of the helmet, it is possible, as shown in 
FIG. 6 and 7, for an additional opening 13 to be shaped in the holder 3, 
plus arrangement of enlarged engagement surfaces 33 which are directed or 
substantially turned towards the direction in which the largest tensile 
stresses occur. In the holder's other end portion and in the vicinity of 
the protruding part 4, it is possible to arrange reinforcement portions 34 
which reinforce the holder's end portion. 
In connection with the manufacturing of the helmet 1, the hood 2 or the 
frame 2', anchoring openings can be arranged for holders 3 which are 
arranged after the frame 2' or the hood has been manufactured and removed 
from the molding tool. In this case holders 3 are shaped as, for example, 
a peg or stud shaped devices, see FIG. 8, with an attachment part 12 which 
can be entered, pushed or pressed or the like into the frame 2' or the 
hood 2 and its material or into said and possibly arranged anchoring 
openings, after which the holders 3 are anchored with the aid of a medium, 
such as glue, by means of ultra-sound, whereby the holders are welded 
secure in the helmet, or by some other appropriate method. The holders 3 
can also show a position device 19 or a fastening device 19 in the shape 
of a barb or the like. The attachment part 12 is shaped sufficiently long 
to ensure the securing of the holder which could also be fixed in the 
frame 2' in the molding tool in connection with the molding of the frame. 
The position devices 15 or 19 also promotes a reliable anchoring of the 
holders in the helmet 1, the hood 2 or the frame 2'. 
Ventilation openings 11 in or through the helmet can be arranged at the 
same time and in the same manufacturing process as the manufacturing of 
the helmet 1, the hood 2 or the frame 2'. According to the invention the 
mold halves are each provided with pins which with a closed molding tool 
together form a bridge through the mold chamber. As per a second method, 
cores or the like are entered into the molding chamber of the molding tool 
which cores are drawn out from the chamber before the separation of the 
tool. Irrespective of which method is used, the limiting surfaces in the 
ventilation openings thus achieved are ensured a high density so that the 
surfaces will be closed and tight. 
In order that the helmet 1 will provide the required protection it must sit 
on the head of the wearer in an intended way and in an assured position. 
For this reason, the hood 2 or the frame 2' is provided with or the helmet 
show support straps 6, 7 chin bands 8 plus a locking device 9 and further 
provided with adjusting devices 5 in the shape of a band distributor plus 
adjustment facilities in the chin band. It is important that the support 
straps and also the chin band have an intended and correct running, for 
which reason holders are arranged partly in front section 31 of the 
helmet, and partly in its rear section 32, back of the head section or 
neck section 36 according to one preferred design. Owing to this, a first, 
front part 6 of the support straps 6, 7, reaches a substantially 
vertically running and a second, rear part 7 of the support straps 6, 7, a 
substantially horizontal running or from the helmet 1 and to a position at 
a distance from and substantially below the ear of the wearer. Thus, the 
support straps 6, 7 will be able to run in a position along the cheek 
section of the wearer and in the direction of the jaw and below and at a 
distance from the ear and on to the back of the head of the wearer or 
neck. The support straps 6, 7 are, according to the embodiment, provided 
with an adjusting device 5 which is arranged to distribute a support strap 
6, 7 in two parts 6 and 7 via a double folded section. To such a double 
folded section, a so-called chin strap 8 can be connected, or via a 
clincher 42. Moreover, to such a double folded section can a or a portion 
16 in a locking device 16 be connected, whereby a second support strap 8 
in the shape of a chin band can be locked round the chin of the wearer or 
the jaw. Other devices, which can be connected, are a chin strap 8 with a 
locking device 9 or a portion 16 of a locking device which are arranged to 
a support strap before that an adjusting device 5 or similar is arranged 
to the support strap 6, 7 which is subsequently arranged with each part 6 
and 7 to protruding parts 4 of the holders 3 and attached or connected 
with the aid of a rivet 18 or similar attachment device. It may be seen to 
be advantageous if the support strap or straps 6, 7, or one or both parts 
6 and 7, can turn in the holders 3 or theirs protruding part 4, which in 
turn will be arranged or shaped as rigid in form or stiff devices. As 
indicated for example in FIG. 1 a first part 6 of the support straps 6, 7 
is arranged in the front section 31 of the helmet and in front of the ear 
of the wearer and a second part 7 of the support straps is arranged in the 
rear section 32 of the helmet, behind the ear of the wearer or arranged in 
one part 36 or parts which will cover the back of the head of the wearer 
and/or parts of the neck of the wearer. Reference designation 37 shows a 
shaping or recess for the ear of the wearer. The front section 31 of the 
helmet can be shaped as a visor 39 or the like. 
In order to ensure substantial protection the helmet must thus sit firmly 
secured on the head of the wearer and cover the forehead and back of the 
head. In this respect the helmet can easily be adjusted in size and 
according to different head shapes with the aid of contact devices 10, 20 
and 30 in the shape of pads or the like which can be shaped such as 
comfort pads and improve the comfort of the helmet and a comfortable 
wearing of the helmet and permits the helmet to lie with an air column or 
an interval space to the head for good ventilation. Therefore, the helmet 
1 comprises pads 10, 20 and 30, of which some pads show different 
configurations. Several such sets of pads can be included and which show 
different thicknesses and are arranged to be easily replaceable for 
adaptation and adjustment, whereby the crown, inner volume or similar of 
the helmet, hood or frame can be changed or adjusted. In FIG. 2 examples 
are shown of how different pads 10, 20 and 30 according to the FIGS. 9-11 
have been arranged in the helmet. The pads can thus be shaped attachable 
in the helmet which can be provided with holding elements 41 for pads, 
such as bur fasteners or the like. The pads can or are in turn shaped from 
a yielding, flexible or other similar material or according to the 
embodiment from a layer of foam plastic material 27 provided with a fabric 
28, 29, as a cotton terry, on both sides for the sake of comfort. The pads 
also provide a certain shock absorbing or energy absorbing effect, even if 
this is not the main purpose with the pads. Furthermore, the length of the 
support straps 6, 7 are adjusted with the aid of the adjusting device 5, 
see the arrow 24 in FIG. 13. On displacement of the adjusting device 5 the 
angles of both parts 6 and 7 of the support straps 6, 7 are changed. The 
length of a second support band 8 or a chin strap can be adjusted with the 
aid of an arranged adjusting element 43 in the shape of a band running 
through the locking device 9 or a portion of this. Adjustment can thus be 
made as shown with the arrow 26 and securing of the adjustment can be made 
with the aid of for example a locking element 44 in the shape of a clasp, 
bur fastener or the like. The arrow 25 will show how a portion of the 
locking device 9 is united with a second portion 16 for locking the helmet 
on the head by means of the locking device 9 and securing with the aid of 
the chin strap 8. 
The adjusting device 5 or the like is formed as a band distributor which 
shows slots 21 to thread bands or straps 6, 7 or a part 6 and 7 in each 
opening 21 and a slot 22 to thread a double folded section or a portion of 
the strap 6, 7 through the slot, to which, as mentioned, different devices 
can be arranged which takes place before the strap 6, 7 is arranged to the 
adjusting device 5. The strap 6, 7 is subsequently arranged to the holders 
3. In addition, the adjusting device 5 shows a contact portion 23 arranged 
as a contact surface or the like and which surface is smooth and mitigates 
the contact and pressure of the band distributor to the cheek or rather to 
the jaw or the neck. 
Despite the relative thickness of the helmet, hood or frame, see reference 
designation 38, the helmet is light and comfortable to wear and ensures by 
virtue of the relatively thick wall a good energy absorbing and shock 
absorbing capacity which is the properties of expanded polystyrene. 
Without exceeding the scope of the concept of the invention, modifications 
of the headgear, the hood or the frame, and the method of producing these, 
should be possible. Thus, the outer design or the form and dimension of 
the helmet are not necessarily decisive, since it is shaped in different 
sizes and for different purposes and for both children and adults. 
Additional attachment points and holders can, of course, be arranged or 
fewer holders if they are shaped together as an unit and molded into the 
frame as a reinforcement which improves the strength of the helmet with 
respect to breaking or cracking. It would therefore be possible within the 
scope of the invention to form and intermediate layer in the helmet of 
another material or another plastic material which is more rigid and 
tougher and above all more impenetrable or impenetrable for particularly 
shape or pointed objects, whereby a helmet according to the invention 
would find further areas of use than the areas primarily thought, such as 
a safety helmet for the children's play, travel in vehicles, the exercise 
of different sports, tobogganing, etc., and as a bicycle or recreation 
helmet or headgear, since it can be used even if one does not engage in 
activities where the risk of injury exists but use it as a headgear. In 
the case of an intermediate layer or a lamination then the said protruding 
parts are able to be shaped in the said intermediate layer and lamination. 
Furthermore, a holder in the form of a bow would not need to be shaped 
with a front and rear attachment device or part, but the bow would be able 
to be arranged for a running across the helmet and protrude on both sides 
for front attachment devices and with another bow for rear attachment 
devices or parts. If it is found appropriate it would be equally practical 
to shape, for example, a plate or the like as a rear attachment device 
which with parts protrudes from the frame and the helmet to form a rear 
attachment device. It is therefore not necessary that the attachment 
devices are shaped from a bow, but they can show whatever other 
appropriate design with respect to positioning and use, for example as a 
neck guard or back of the head reinforcing device. 
The headgear, helmet, hood or frame according to the invention or the 
method to produce them are thus not restricted to what has been shown and 
described in connection with the embodiments but solely by the following 
claims.