Abstract:
A ventilation system for a helmet that incorporates various elements in different embodiments, including air flow channels in the safety padding, a shell on the safety padding underneath the external shell, thickening of the external shell in the areas of the air flow channels, extrusions in the external shell to facilitate air flow in the air flow channels, and vents in the external shell to feed and exhaust air flow.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of Invention  
         [0002]     The invention relates in general to the field of helmets, and more specifically to a ventilation system for a motorcycle helmet.  
         [0003]     2. Description of Related Art  
         [0004]     Safety helmets for motorcycles are typically made in the form of a complete cap that provides an opening in the area of the user&#39;s eyes. The helmets are generally provided with an external shell, made from a rigid and strong material, such as polycarbonate, or composite materials, coupled with safety padding inside the shell. The safety padding is often made of expanded polystyrene, expanded polypropylene, or foamed polyurethane, and is itself often lined with a soft material in order to provide comfort to the wearer.  
         [0005]     Ventilation is often required both for cooling and to exhaust moisture caused by sweat coming from the rider. The need for ventilation occurs both in the volume under the main shell and in the area of the cheek bar.  
         [0006]     Prior art devices have addressed the need for ventilation in motorcycle helmets. For example, U.S. Pat. No. 5,086,520 to Arai utilizes an air inlet on the top portion of the shell to allow for the introduction of air into the shell. This device delivers air to the top of the head and is limited in the manner in which it can cool or dehumidify the interior of the helmet shell.  
         [0007]     U.S. Pat. No. 4,555,816 to Broersma illustrates a motorcycle helmet which utilizes air inlets in the cheek bar. Although the air inlet is in the external portion of the cheek bar, the air itself is routed outside the foamed polyurethane liner and then through passages where it can then ventilate the sides, top, and rear of the user&#39;s head.  
         [0008]     A safety concern for helmets is the helmet&#39;s ability to resist penetration of an object through the outer shell. In some helmets, the safety padding is made of expanded polystyrene. In such helmets, the safety padding may tend to split if penetrated by an object, especially if the safety padding has been thinned or had channels added. This aspect of the safety padding may require a helmet to have other modifications in conjunction with adding channels to the safety padding in order to provide maximal penetration resistance.  
         [0009]     Prior methods are limited in their ability to provide ventilation to cool the rider&#39;s head. What is called for is a better ventilation system for a helmet that maintains the integrity and safety of the helmet. Such a helmet may utilize better ventilation channels while maintaining maximum penetration protection.  
       BRIEF SUMMARY OF THE INVENTION  
       [0010]     A ventilation system for a helmet that incorporates various elements in different embodiments, including air flow channels in the safety padding, a shell on the safety padding underneath the external shell, thickening of the external shell in the areas of the air flow channels, extrusions in the external shell to facilitate air flow in the air flow channels, and vents in the external shell to feed and exhaust air flow. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]      FIG. 1  is a front view of a helmet according to one embodiment of the present invention.  
         [0012]      FIG. 2  is a side view of a helmet according to one embodiment of the present invention.  
         [0013]      FIG. 3  is a side cut-away view of a helmet according to one embodiment of the present invention.  
         [0014]      FIG. 4  is a front cut-away view of a helmet according to one embodiment of the present invention.  
         [0015]      FIG. 5  is a rear view of the safety padding of the helmet according to one embodiment of the present invention.  
         [0016]      FIG. 6  is a bottom view of the safety padding of the helmet according to one embodiment of the present invention.  
         [0017]      FIG. 7  is a side cut-away view of a helmet according to one embodiment of the present invention.  
         [0018]      FIG. 8  is a front cut-away view of a helmet according to one embodiment of the present invention.  
         [0019]      FIG. 9  is a side cut-away view of a helmet according to one embodiment of the present invention.  
         [0020]      FIG. 10  is a front cut-away view of a helmet according to one embodiment of the present invention. 
     
    
     DETAILED DESCRIPTION  
       [0021]     In some embodiments of the present invention, as seen in  FIG. 1 , a motorcycle helmet  100  has an outer shell  101  and safety padding  102 . The outer shell has a chin bar  107  in some embodiments. In some embodiments, the chin bar  107  is integral to the outer shell  101 . In some embodiments, the chin bar  107  is attached to the outer shell  101 . The face opening  106  in the outer shell  101  is an opening that allows for the user to see out and is typically large enough to allow for the user to wear a pair of goggles or other eyewear. The visor  103  is attached to the outer shell  101  and can be used to provide shade to the face opening  106  while the helmet  100  is worn by the user.  
         [0022]     Above the face opening  106  in the outer shell  101  are front vents  110 ,  111 . In some embodiments, the front vents  110 ,  111  are capped by front vent mechanisms  104 ,  105  which can be opened and closed to adjust the amount of airflow that can travel through the front vents  110 ,  111 . In some embodiments, the front vents  110 ,  111  are located under the visor  103  and above the face opening  106 . In some embodiments, the front vents  110 ,  111  are located in the outer shell  101  in an area substantially over channels in the safety padding. The front vents  110 ,  111  allow for fluidic coupling of the channels in the safety padding, or of the channels in the outer shell, or of both, to the outside airflow.  
         [0023]     In some embodiments of the present invention, as seen in  FIG. 2 , the outer shell has rear vents. In some embodiments, the outer shell has one or more upper rear vent  121  and one or more lower rear vent  123 . The upper rear vents  121  may have an upper rear vent cover  120  in some embodiments. The lower rear vents  123  may have a lower rear vent cover  122  in some embodiments. In some embodiments, the rear vents are located in an area substantially over channels in the safety padding. The rear vents may allow for fluidic coupling of the channels in the safety padding to the outside airflow.  
         [0024]      FIGS. 3 and 4  represent typical cross-sections of the motorcycle helmet  100  according to one embodiment of the present invention. The outer shell  101  receives airflow  302 ,  303  through a front vent  110 . Air flow may exhaust through upper rear vent  121  and the lower rear vent  123 . The front vent  110 , the upper rear vent  121 , and the lower rear vent  123  may located such that they substantially overlay the airflow channels in the safety padding in some embodiments. In some embodiments, there are two front vents, two upper rear vents, and two lower rear vents.  
         [0025]     In some embodiments of the present invention, the air flows through outer channels  401  along the exterior surface of the safety padding  102  in some embodiments. The airflow  303 ,  304 ,  305 ,  306  through the safety padding  102  flows through holes  402  that fluidically couple the outer channels  401  along the exterior of the safety padding  102  to the inner surface of the safety padding  102 . The safety padding  102  has inner channels  406  along its inner surface in some embodiments. The bottom surface  307  of the outer channels  401  are coupled to the bottom surface  308  of the inner channels  406  via holes  402  in some embodiments. The comfort liner  301  resides along the inside of the safety padding  102  in some embodiments.  
         [0026]     In some embodiments, the holes are significantly larger. The increased size of the holes and channels enhances ventilation of the helmet interior even when the relative airflow speed outside the helmet is minimal.  
         [0027]     In some embodiments of the present invention, the outer shell  101  has raised areas  404 ,  405  that contribute to the formation of an airflow channel. The raised areas  404 ,  405  may substantially overlay the outer channels  401  in the safety padding  102 . In some embodiments, the space  403  between the safety padding  102  and the outer shell  101  may allow for some air flow, even in the area away from the outer channels  401 . In some embodiments, the outer contour of the safety padding in the areas other than the outer channels  401  substantially conforms to the inner contour of the outer shell  101 . In some embodiments, the raised areas  404 ,  405  of the outer shell  101  may be reinforced. In some embodiments, the regions may not be raised but are reinforced. In some embodiments, the reinforcement consists of additional thickness in the outer shell.  
         [0028]     The reinforcement of the outer shell enhances the penetration resistance in the area of reinforcement. In areas where the safety padding may be thinner or partially removed to allow for better airflow or for other reasons, the reinforcement of the outer shell can be used to compensate for any possible reduction of strength, or reduction of penetration resistance, of the helmet in this area.  
         [0029]     In some embodiments of the present invention, as seen in  FIGS. 5 and 6 , the safety padding  102  may have a padding shell  501 . In some embodiments, the padding shell  501  resides on the outer surface of the safety padding  102 . In some embodiments, the padding shell  501  covers a portion of the outer surface of the safety padding  102 , whereas the remainder  502  of the outer surface of the safety padding not covered by the padding shell  501 . In some embodiments, the padding shell  501  covers substantially all of the outer surface of the safety padding  102 . In some embodiments, the padding shell  501  substantially conforms to the contours of the outer surface of the safety padding  102 . In some embodiments, the padding shell  501  is a polycarbonate material. In some embodiments, the polycarbonate material is approximately 0.050 inches thick.  
         [0030]     In one embodiment of the present invention, as seen in  FIG. 5 , the padding shell  501  resides on the outer surface of the safety padding. The padding shell  501  conforms to the contours of the outer surface of the safety padding  102 . The padding shell  501  does not cover all of the outer surface of the safety padding  102  in some embodiments. The outer channels  504 ,  505  have their surface covered by the padding shell  501 . The outer channels run substantially longitudinally in some embodiments. Portions of the interior surfaces of the holes  506 ,  507  in the outer channels  504 ,  505  are covered by the padding shell  501  in some embodiments. All of the interior surfaces of the holes  506 ,  507  in the outer channels  504 ,  505  are covered by the padding shell  501  in some embodiments.  
         [0031]     In some embodiments of the present invention, there is one outer channel on the outer surface of the safety padding. In some embodiments, there are two outer channels on the outer surface of the safety padding. In some embodiments, there is a plurality of outer channels on the outer surface of the safety padding.  
         [0032]     The padding shell  501  is bonded to the outer surface of the safety padding  102  in some embodiments. The padding shell  501  may increase the penetration resistance of the helmet in a variety of ways. The padding shell itself typically is much more resistant to penetration than the safety padding that it covers. Should an item penetrate the outer shell, it must then also penetrate the padding shell in some areas. Should an item penetrate the outer shell, the item may then split the safety padding and force the split pieces apart. Should the item penetrate a helmet that has a padding shell, it will be harder for the pieces of the safety padding to be split apart because of the bonding of the padding shell to the safety liner. In some embodiments, the material of the padding shell is not as susceptible to splitting, and may anchor the safety padding together.  
         [0033]     In some embodiments, the padding shell and safety padding form a composite to create a stronger structure. In some embodiments, the padding shell is molded into the safety padding. In some embodiments, the padding shell is bonded to the safety padding. In some embodiments, the padding shell is attached to the safety padding using other methods.  
         [0034]     In some embodiments, as seen in  FIG. 6 , the safety padding  102  has inner channels  604 ,  605  on the interior surface. In some embodiments, the safety padding  102  has one inner channel on its interior surface. In some embodiments, the safety padding  102  has a plurality of inner channels on its interior surface. In some embodiments, the outer channels  504 ,  505  substantially overlay the inner channels  604 ,  605 . In some embodiments, the through holes  506 ,  507  in the safety padding  102  directly couple the outer channels  504 ,  505  and the inner channels  604 ,  605 . In some embodiments, the through holes are approximately 20 mm wide and 70 mm long. In some embodiments, the outer channels are approximately 5 mm to 10 mm deep.  
         [0035]      FIGS. 7 and 8  represent typical cross-sections of the motorcycle helmet  550  according to another embodiment of the present invention. The outer shell  551  receives airflow  552  through one or more front vents  553 . Air flow may exhaust through one or more upper rear vents  554 . In some embodiments, there is one or more lower rear vents. The front vents  553 , the upper rear vents  554 , and the lower rear vents may be located such that they substantially overlay the airflow channels in the safety padding  561  in some embodiments. In some embodiments, there are two front vents, two upper rear vents, and two lower rear vents.  
         [0036]     A face opening vent  555  allows for airflow  556  for additional ventilation entering from the face opening  106  in some embodiments. In some embodiments, there are two face opening vents  555 . In some embodiments, there are a plurality of face opening vents  555 . In some embodiments, the face opening vent  555  is a continuous vent. A face opening shield  557  may be used to direct airflow  556  into the helmet  550 . In some embodiments, the face opening shield  555  directs airflow into the inner channels. The comfort liner  558  lines the inner surface of the safety padding  561  in some embodiments. Gaps  560  in the comfort liner  558  facilitate ventilation into the interior of the helmet  550 .  
         [0037]     In some embodiments, the safety padding  561  has larger channels for greater ventilation. In some embodiments, the safety padding has internal reinforcements  559 . In some embodiments, the internal reinforcements  559  are made of ABS. In some embodiments, the internal reinforcements are molded into the safety padding  561 . The internal reinforcements  559  add strength to the safety padding  561 , especially in the areas of the larger channels. In some embodiments, the safety padding  561  has larger channels, internal reinforcements  559 , and a padding shell.  
         [0038]     In some embodiments, the outer shell  551  of the helmet  550  has raised areas  562  that contribute to the formation of an airflow channel. The raised areas  562  may substantially overlay the larger channels  563  in the safety padding  561 . In some embodiments, the front vents  553  are located at the front of the raised areas  562 . In some embodiments, the outer contour of the safety padding in the areas other than the larger channels  563  substantially conforms to the inner contour of the outer shell  551 . In some embodiments, the raised areas  562  of the outer shell  551  may be reinforced. In some embodiments, the regions may not be raised but are reinforced. In some embodiments, the reinforcement consists of additional thickness in the outer shell.  
         [0039]      FIGS. 9 and 10  represent typical cross-sections of the motorcycle helmet  650  according to another embodiment of the present invention. The outer shell  651  receives airflow  652  through one or more front vents  653 . Air flow may exhaust through one or more upper rear vents  654 . In some embodiments, there is one or more lower rear vents  670 . The front vents  653 , the upper rear vents  654 , and the lower rear vents  670  may be located such that they substantially overlay the airflow channels in the safety padding  661  in some embodiments. In some embodiments, there are two front vents  653 , two upper rear vents  654 , and two lower rear vents  670 .  
         [0040]     A face opening vent  655  allows for airflow  656  for additional ventilation entering from the face opening  106  in some embodiments. In some embodiments, there are two face opening vents  655 . In some embodiments, there are a plurality of face opening vents  655 . A face opening shield  657  may be used to direct airflow  656  into the helmet  650 . In some embodiments, the face opening shield  655  directs airflow into the inner channels  671 . The comfort liner  658  lines the inner surface of the safety padding  661  in some embodiments. Gaps  660  in the comfort liner  658  facilitate ventilation into the interior of the helmet  650 .  
         [0041]     In some embodiments, the safety padding has internal reinforcements  659 . In some embodiments, the internal reinforcements are made of ABS. In some embodiments, the outer shell  651  of the helmet  650  has raised areas  662  that contribute to the formation of an airflow channel. The raised areas  662  may substantially overlay the outer channels  663  in the safety padding  661 . In some embodiments, the raised areas  662  may be reinforced.  
         [0042]     As evident from the above description, a wide variety of embodiments may be configured from the description given herein and additional advantages and modifications will readily occur to those skilled in the art. The invention in its broader aspects is, therefore, not limited to the specific details, representative apparatus and illustrative examples shown and described. Accordingly, departures from such details may be made without departing from the spirit or scope of the applicant&#39;s general inventive concept.