Strap anchor system and method

In accordance with the teachings of the present invention, a strap anchor system and method are provided. In a particular embodiment of the present invention, the system includes a helmet body, a support structure substantially disposed within the helmet body, and a strap anchor housing coupled to the support structure and substantially disposed within the helmet body. The strap anchor housing is operable to receive a strap anchor after formation of the helmet body. The strap anchor is operable to couple a strap to the strap anchor housing so that a load on the strap is transferred to the support structure before being transferred to the helmet body.

TECHNICAL FIELD OF THE INVENTION

The present invention relates generally to protective headgear and more particularly to a strap anchor system and method.

BACKGROUND OF THE INVENTION

A physical impact to the head of a person may cause serious injury or death. To reduce the probability of these injuries, protective headgear, such as a helmet, is often used in activities associated with an increased risk of such injuries. Examples of such activities include skiing, snowboarding, bicycling, rollerblading, rock climbing, skateboarding, and motorcycling, among others. In general, a helmet is designed to maintain its structural integrity and stay secured to the head of a wearer during an impact. Typically, a helmet retention system comprised of one or more straps is used to secure the helmet to the head of the wearer.

SUMMARY OF THE INVENTION

In accordance with the teachings of the present invention, a strap anchor system and method are provided. In a particular embodiment of the present invention, the system comprises a helmet body, a support structure substantially disposed within the helmet body, and a strap anchor housing coupled to the support structure and substantially disposed within the helmet body. The strap anchor housing is operable to receive a strap anchor after formation of the helmet body. The strap anchor is operable to couple a strap to the strap anchor housing so that a load on the strap is transferred to the support structure before being transferred to the helmet body.

A technical advantage of particular embodiments of the present invention may include the ability to couple a helmet retention system to a support structure, such as a roll cage, after the support structure has been in-molded in a helmet body. This helps reduce the cost and complexity of manufacturing the helmet.

Another technical advantage of particular embodiments of the present invention may include the ability to couple a helmet retention system with a helmet without the use of external strap bones that clutter the external appearance of the helmet and impede the application of graphics to the outer surface of the helmet.

Other technical advantages of the present invention may be readily apparent to one skilled in the art from the following figures, descriptions, and claims. Moreover, while specific advantages have been enumerated above, various embodiments may include all, some, or none of the enumerated advantages.

DETAILED DESCRIPTION OF THE INVENTION

In accordance with the teachings of the present invention, a strap anchor system and method are provided. In particular embodiments, the strap anchor system comprises a helmet body, a support structure substantially disposed within the helmet body, and a strap anchor housing coupled to the support structure. The strap anchor housing is operable to couple a strap to the support structure so that a load on the strap is transferred to the support structure before being transferred to the helmet body. Such a strap anchor system allows for the coupling of a helmet retention system to an in-molded support structure, such as a roll cage, after formation of the helmet body. In particular embodiments, this post-molding coupling of the helmet retention system may reduce the cost and complexity of manufacturing the helmet. Moreover, strap anchors in accordance with particular embodiments of the present invention need not rely on external strap bones. This allows for a more aesthetically pleasing external appearance and facilitates the application of graphics to the outer surface of the helmet body.

FIG. 1illustrates one embodiment of an environment100in which a helmet110in accordance with a particular embodiment of the present invention may be used. As shown inFIG. 1, environment100includes a bicyclist (user)102riding a bicycle104and wearing helmet110. Helmet110may be secured to head106of user102using one or more straps108, which along with any other devices having a primary function of securing helmet110to head106, may be referred to as a “helmet retention system.” As used herein, the term “helmet” refers to any type of protective headgear, such as a bicycle helmet, a motorcycle helmet, or a hardhat. Furthermore, although helmet110is used as an example to describe some embodiments of the present invention, any type of helmet, both protective and non-protective, may benefit from the teachings of the present invention.

If user102were to accidentally fall off bicycle104, user102could suffer various injuries, including head trauma. Therefore, helmet110is designed to remain secured to head106during an impact and maintain its structural integrity to better protect head106. As a secondary consideration, helmet110may also be designed to have an attractive appearance. For example, many users find a helmet with a sleek external appearance to be attractive. Such a sleek external appearance also facilitates the application of graphics to the external surface of the helmet.

Another example of a helmet is shown inFIGS. 2A-B, which illustrate two different views of a helmet200in accordance with a particular embodiment the present invention.FIG. 2Aillustrates a perspective view of helmet200, whileFIG. 2Billustrates a cross-section of helmet200at a phantom line208shown inFIG. 2A. Similar to helmet110inFIG. 1, helmet200is designed to remain secured to the head of a user during an impact and maintain its structural integrity to better protect the user's head.

As shown inFIGS. 2A and 2B, helmet200generally comprises a helmet body210having an outer surface212and an inner surface216. Helmet200also comprises a protective layer or shell202disposed on the outer surface212of body210and a support structure220disposed substantially within body210.

Generally, helmet body210may be formed from any suitable material that can protect the head106(FIG. 1) of user102(FIG. 1), such as expandable polystyrene (EPS), while protective layer202may be formed from any suitable material that can protect helmet body210, such as polycarbonate plastic. Protective layer202may also be used to add color, pictures, patterns, and/or any other design elements to helmet200.

As mentioned above, helmet200also includes a support structure220disposed substantially within body210. Generally, support structure220provides one or more attachment points for a helmet retention system that may be used to secure helmet200to the head of a user. In particular embodiments, support structure220may also help improve the structural integrity of helmet200. Examples of suitable support structures200may include a roll cage, a butterfly, or any other structure than may be in-molded in a helmet body to provide an attachment point for a strap anchor system in accordance with the teachings of the present invention. An example of one such support structure220is illustrated inFIGS. 3A and 3B.

FIGS. 3A and 3Billustrate a roll cage300that utilizes an strap anchor system in accordance with a particular embodiment of the present invention. As shown inFIGS. 3A and 3B, roll cage300generally comprises a plurality of members302that are coupled with each other through a plurality of junctions304. These members302may be formed from a plastic material (such as ZYTEL ST 801™) or another suitably tough material. In particular embodiments of the present invention, roll cage300may also include slots and/or attachment points to couple a helmet retention system to roll cage300.

Roll cage300is configured to receive one or more strap anchor housings306, which are each operable to couple a strap anchor316(FIG. 3D) to roll cage300. As shown inFIGS. 3A and 3B, strap anchor housings306are typically distinct components, separate from roll cage300. However, in particular embodiments of the present invention, strap anchor housings306may be formed integrally with roll cage300. Similarly, a helmet retention system is typically coupled to roll cage300after roll cage300has been in-molded in a helmet body, such as helmet body210inFIG. 2B. However, particular embodiments of the present invention may couple straps anchors316(FIG. 3D) to roll cage300prior to molding. These embodiments, however, may not benefit from the reduced manufacturing complexity seen in other embodiments that employ post-molding insertion of the strap anchors316.

Generally, each strap anchor housing306is configured to received a strap anchor housing cover308and a strap anchor housing insert310. Housing cover308and housing insert310each help prevent EPS or other material from entering housing306during molding and clogging the interior of the housing. In particular embodiments of the present invention, housing cover308may be formed separately from strap anchor housing306. This facilitates the formation and machining of the internal components of the housing306. However, in other embodiments of the present invention, housing cover308may be formed integrally with strap anchor housing306within the teachings of the present invention.

As mentioned above, strap anchor housing306is also configured to receive strap anchor housing insert310. Like housing cover308, insert310also helps prevent EPS or other material from entering strap anchor housing306during molding. Strap anchor housing insert310also helps form a channel in the helmet body (not illustrated) during formation the helmet body around roll cage300though which strap326(FIG. 3D) and strap anchor316(FIG. 3D) may be coupled with housing306. Housing insert310is configured to be removeably coupled with housing306. After roll cage300and housing306have been molded into a helmet body, insert310may be removed from housing306, leaving in its place the channel between housing306and an inner surface of the helmet body. Through this channel, strap anchor316(FIG. 3D) may be coupled with strap anchor housing306.

In particular embodiments of the present invention, strap housing insert310may also be used to help position roll cage300in a mold prior to formation of the helmet body. In such an embodiment, insert300may be removeably coupled with a connector330on the male (convex) portion328of the mold to properly position roll cage300in the mold. After formation of the helmet body, insert310may be decoupled and removed from the mold.

Particular embodiments of the present invention may use a variety of mechanisms to couple a helmet retention system to strap anchor housing306and/or to couple strap anchor housing306to roll cage300. One such mechanism is illustrated inFIGS. 3C and 3D. AlthoughFIGS. 3C and 3Ddo not illustrate a helmet body encompassing roll cage300, it should be understood that strap326and strap anchors316are typically coupled to roll cage300after roll cage300has been molded into a helmet body.

Generally, strap anchor housing306is configured to be coupled with roll cage300, sitting in an opening312between two approximately parallel members302. In particular embodiments of the present invention, these approximately parallel members302may be angled toward each other such that members302approach each other as they approach the inner surface of the helmet body. So arranged, housing306may sit in, but not be pulled through, opening312. This helps ensure housing306will not become decoupled from roll cage300under stress. In particular embodiments, housing306may be further coupled to roll cage300using a plurality of clips324to lock housing306into place. However, any suitable method may be used to couple housing306to roll cage300, in accordance with the teachings of the present invention.

Generally, strap anchor housing306is configured to receive a strap anchor316on the end of a strap326. Although embodiments of the present invention may differ, in particular embodiments, strap anchor316comprises a pin320secured in a loop318. Loop318may be formed by folding strap326back over on itself and stitching, or “bar-tacking,” the strap326in place. Held in place by loop318, pin320may then be inserted into and coupled with housing306.

In particular embodiments of the present invention, the coupling of strap anchor316and housing306may be accomplished by securing pin320in a pin cradle322in the strap anchor housing306. In particular embodiments, securing pin320in pin cradle322may be facilitated by flexible tab314, which extends from roll cage300into housing306. In these embodiments, strap anchor316may be inserted in housing306such that flexible tab314is pushed to the side of housing316during insertion. With tab314pushed to the side, pin320may be freely inserted into housing306. Tab314may then spring back into its original position, as shown inFIG. 3D, helping to position and/or secure pin320in pin cradle322.

A variety of other mechanisms of securing strap anchor316in housing306may be used in accordance with the teachings of the present invention. For example, in particular embodiments housing306may employ a ratcheting mechanism to secure pin320so that pin320may not be removed once inserted. As pin320is inserted to housing306, pin320may encounter a series of teeth (not illustrated) that engage pin320to prevent its removal. These teeth allow pin320to be inserted into, but not removed from, housing306. In other embodiments, pin320may comprise an expandable pin that extends once inserted into housing306. In particular embodiments, this expandable pin320may comprise a spring-loaded pin. Once extended, the ends of pin320may then fit into a pin cradle322or a slot (not illustrated) to secure pin320in housing306. With the benefit of this disclosure, other suitable mechanisms for securing pin320in housing306should be apparent to one skilled in the art, all of which fall within the teachings of the present invention.

Given that strap anchor housing306may be substantially encompassed by a helmet body, particular embodiments of the present invention may employ insertion tools (not illustrated) to facilitate the coupling of strap anchor316with strap anchor housing306. For example, a flat blade may be used to force strap anchor316through the channel in the helmet body (not illustrated) left by housing insert310and into position in housing306. After strap anchor316is in place in housing306, the blade may be removed from the channel, leaving strap326securely coupled to roll cage300by strap anchor316and strap anchor housing306.

AlthoughFIG. 3Ddescribes a strap anchor316that generally comprises a pin320secured in a fabric loop318, other embodiments of the present invention may employ a variety of different strap anchors. For example, particular embodiments of the present invention may employ a strap anchor comprising a relatively rigid piece of plastic or other suitable material that is coupled to housing306after formation of the helmet body and extends beyond the inner surface of the helmet body. In such an embodiment, strap326may be coupled with the strap anchor outside of the helmet body. The use of such a relatively rigid strap anchor may facilitate the coupling of strap anchor to housing306and even obviate the need for additional insertion tools. Such a strap anchor may also allow for straps326to be coupled and decoupled from the strap anchor without requiring strap anchor to be first decoupled from roll cage300. Other benefits of various strap anchor designs will be apparent to one skilled in the art with the benefit of this disclosure.

A better understanding of the strap anchor system and method of the present invention may be had by making reference toFIG. 4, which illustrates a flowchart400of a method for coupling a helmet retention system to a helmet using an strap anchor system in accordance with a particular embodiment of the present invention.

Flowchart400begins in block401. One or more strap anchors housings are then coupled to a roll cage in block402. In particular embodiments this is done by clipping each of the housings into place in an opening in the roll cage designed to receive them. Once the strap anchor housings are coupled to the roll cage, each housing is then coupled with a respective housing cover in block403to prevent EPS or other materials from entering the housing during molding. The roll cage and covered strap anchor housings are then positioned in the female (concave) portion of a helmet mold in block404.

At block405, a strap anchor housing insert for each strap anchor housing is positioned in the male (convex) portion of the helmet mold. In particular embodiments of the present invention, this may be accomplished by removeably coupling the insert with a connector on the male portion of the mold. The male and female portions of the helmet mold are then closed together in block406such that each insert is coupled with its respective strap anchor housing. In this manner, the inserts may also be used to properly position the roll cage within the helmet mold. The strap anchor housing inserts also define a channel between each strap anchor housing and the inner surface of the helmet being molded. The helmet mold is then filled with EPS, or another suitable material, and is heated to form a helmet body around the roll cage and strap anchor housings at block407. The molded helmet is then removed from the mold at block408.

Once the molded helmet is removed from the mold, the strap anchor housing inserts are removed from the molded body at block409, leaving behind a channel from each strap anchor housing to the inner surface of the helmet body. Through this channel, a helmet retention system comprising one or more straps may be coupled with the roll cage in block410. Using a flat blade, or other suitable insertion tool, a strap anchor on the end of each strap may be inserted into and coupled with its respective strap anchor housing in-molded in the helmet body. After insertion of the strap anchors, the flowchart terminates at block411.

Although flowchart400describes a particular order of step for coupling a helmet retention system with a helmet in accordance with a particular embodiment of the present invention, particular embodiments of the present invention may use all, some, or none of the steps described above. Moreover, particular embodiments may perform those steps in a different order than that described above without departing from the teachings of the present invention. Similarly, the method described in flowchart400is not limited to roll cages, but may be employed with other support structures in accordance with the teachings of the present invention.

Strap anchor systems in accordance with particular embodiments of the present invention may offer numerous advantages over other strap anchor systems. For example, by allowing for post-molding coupling of the straps of the helmet retention system with a support structure, such as a roll cage, particular embodiments of the present invention reduce the cost and complexity of manufacturing helmets. Particular embodiments of the present invention may also offer the ability to couple the straps of the helmet retention system to the helmet without the use of external strap bones or other devices that may reduce the aesthetic appeal of the helmet or impede the application of graphics to the outer surface of the helmet body.