Patent Publication Number: US-10321729-B2

Title: Helmet and method for manufacturing thereof

Description:
PRIORITY 
     This application claims priority of Finnish application number FI 20165503, filed on Jun. 17, 2016, and the contents of which is incorporated herein by reference. 
     TECHNICAL FIELD 
     The invention concerns in general the technical field of helmets. Especially the invention concerns systems for the safety of helmets, such as motorcycle, motocross, snowmobile, ski, snowboard, skateboard helmets, etc., with attached accessories. 
     BACKGROUND 
     Attaching accessories to a helmet can yield the helmet unsafe to wear. For example, a camera attached to a helmet may penetrate through the helmet and cause significant damage to the user. The helmet can become also dangerous if the accessory is mounted rigidly so that in an event of an impact to the accessory, the impact will cause tangential force or torque to user&#39;s head and can thus cause severe damages. 
     Some attempted solutions exist which utilize mounting platforms, base or rails attached to the surface of the helmet on which the accessory such as camera has been attached. These solutions can make the use of camera more comfortable but doesn&#39;t prevent the accessory to cause danger. 
     Some attempts utilize magnets for attaching the accessories to the helmet. While the accessory can detach from the magnet quite easily in case of an impact, the magnet itself is still rigidly attached to the helmet and can become dangerous. 
     There is still need for a helmet to which accessories can be attached without jeopardizing the safety of the helmet. 
     SUMMARY 
     An objective of the invention is to present a helmet and a method for producing a helmet. Another objective of the invention is that the helmets and the method for producing the helmets provide safety for the user attaching accessories to the helmet. 
     The objectives of the invention are reached by helmets and a method as defined by the respective independent claims. 
     According to a first aspect of the present invention, a helmet comprising a first protective layer is provided. The first protective layer comprises at least one accessory mount portion for receiving an accessory mount. The at least one accessory mount portion is being arranged integrally as a part of the first protective layer and configured to disintegrate from the rest of the first protective layer in response to a mechanical impact to the at least one accessory mount portion. 
     The accessory mount portion may comprise an accessory mount base for receiving the accessory mount or an accessory. 
     The accessory mount portion may comprise an inner surface and an outer surface. The inner surface may face an inside volume of the helmet and the outer surface may face outer side of the helmet. The outer surface may face an opposite direction with respect to the inner surface, and wherein the outer surface is larger than the inner surface. 
     The helmet may further comprise at least one protective element arranged substantially in a corresponding position relative to the at least one accessory mount portion for preventing the at least one accessory mount portion from penetrating through the helmet. Said protective element may, preferably, be arranged directly under the at least one accessory mount portion, ‘under’ referring herein to a position between the at least one accessory mount portion and the user&#39;s head when the helmet is used in a normal manner for protecting the user&#39;s head. There may further be a second protective layer arranged between said protective element and the user&#39;s head. 
     The helmet may comprise a volume between the at least one accessory mount portion and the corresponding protective element to provide space for the at least one accessory mount portion to move in response to the mechanical impact to the at least one accessory mount portion. 
     The at least one accessory mount portion may consist of material withstanding without breaking a lower mechanical impact to the at least one accessory mount portion with respect to the material of the first protective layer. 
     The first protective layer may comprise at least one weakening portion configured to break in response to the mechanical impact to the at least one accessory mount portion for disintegrating the at least one accessory mount portion from the rest of the first protective layer. 
     The at least one weakening portion may consist of material withstanding without breaking a lower mechanical impact to the at least one accessory mount portion with respect to the material of the first protective layer. 
     The at least one weakening portion may comprise a groove configured to break in response to the mechanical impact to the at least one accessory mount portion for disintegrating the at least one accessory mount portion from the rest of the first protective layer. 
     The at least one weakening portion may comprise a perforation configured to break in response to the mechanical impact to the at least one accessory mount portion for disintegrating the at least one accessory mount portion from the rest of the first protective layer. 
     The at least one weakening portion may comprise a plurality of holes. At least one of the plurality of holes may have a depth in the direction of the thickness of the first protective layer less than the thickness of the first protective layer. The plurality of holes may be configured to break in response to the mechanical impact to the at least one accessory mount portion for disintegrating the at least one accessory mount portion from the rest of the first protective layer. 
     The at least one weakening portion may be arranged around the at least one accessory mount portion defining a portion of the first protective layer with an unsymmetrical shape for disintegrating the at least one accessory mount portion in response to a lower mechanical impact from a first direction with respect to a mechanical impact from a second direction perpendicular to the first direction. 
     According to a second aspect of the present invention, a method for manufacturing a helmet is provided. The method comprises obtaining a first protective layer, and arranging at least one accessory mount portion integrally to the first protective layer by molding, such as by injection plastic molding, at least one weakening portion to the first protective layer. The at least one weakening portion may be configured to disintegrate the at least one accessory mount portion from the rest of the first protective layer in response to a mechanical impact to the at least one accessory mount. 
     The helmet according to the present invention provides safety for the user wearing accessories attached to helmet. Especially the helmet provides safety against the hard accessories, typically having sharp edges, attached to outer surface of the helmet and residing outside of the helmet. The helmet according the present invention comprises at least one accessory mount portion which disintegrates from the helmet rather than penetrates through the helmet in case of a mechanical impact to the accessory mount portion or the accessory itself. 
     The expression “a number of” refers herein to any positive integer starting from one, e.g. to one, two, or three. 
     The expression “a plurality of” refers herein to any positive integer starting from two, e.g. to two, three, or four. 
     The terms “first” and “second” do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. 
     The exemplary embodiments of the invention presented in this patent application are not to be interpreted to pose limitations to the applicability of the appended claims. The verb “to comprise” is used in this patent application as an open limitation that does not exclude the existence of also un-recited features. The features recited in depending claims are mutually freely combinable unless otherwise explicitly stated. 
     The novel features which are considered as characteristic of the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objectives and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF FIGURES 
       The embodiments of the invention are illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings. 
         FIG. 1  illustrates schematically a helmet comprising an accessory mount portion according to an embodiment of the present invention. 
         FIG. 2  illustrates schematically a helmet comprising an accessory mount portion and a protective element according to an embodiment of the present invention. 
         FIG. 3  illustrates schematically a helmet comprising two accessory mount portions and a protective element arranged in corresponding positions with respect to the two accessory mount portions according to an embodiment of the present invention. 
         FIG. 4  illustrates schematically a helmet comprising an accessory mount portion and an accessory mount base according to an embodiment of the present invention. 
         FIG. 5  illustrates schematically a helmet comprising an accessory mount portion and an accessory mount base or an accessory mount to which an accessory, in this example a camera, has been mounted according to an embodiment of the present invention. 
         FIGS. 6A-6B  illustrate cutaway and section views of an accessory mount portion according to an embodiment of the present invention consisting of a material withstanding without breaking a lower mechanical impact to the accessory mount portion with respect to the material of the first protective layer. 
         FIGS. 7A-7C  illustrate cutaway and section views of at least one weakening portion comprising a groove according to an embodiment of the present invention. 
         FIGS. 8A-8B  illustrate cutaway and section views of at least one weakening portion comprising a perforation according to an embodiment of the present invention. 
         FIGS. 9A-9B  illustrate cutaway and section views of at least one weakening portion comprising a plurality of holes according to an embodiment of the present invention. 
         FIGS. 10A-10B  illustrate cutaway and section views of at least one weakening portion comprising material withstanding without breaking a lower mechanical impact to the accessory mount portion with respect to the material of the first protective layer according to an embodiment of the present invention. 
         FIGS. 11A-11B  illustrate cutaway and views of at least one weakening portion comprising at least one hole or groove having a depth in the direction of the thickness of the first protective layer less than the thickness of the first protective layer according to an embodiment of the present invention. 
         FIG. 12  illustrates a flow diagram of the method according to the present invention. 
     
    
    
     DESCRIPTION OF SOME EMBODIMENTS 
       FIG. 1  illustrates schematically a helmet according to an embodiment of the present invention. The helmet  100  comprises a first protective layer  12 . The first protective layer  12  is typically the outermost layer of the helmet  100  and is adapted to receive a mechanical impact in cases, for example, where the user falls and hits his head to the ground. The main task of the first protective layer  12  is to cover the user&#39;s head from direct impacts and to distribute the energy of the impact to larger surface than the contact surface of the object causing the impact. The first protective layer  12  may be, for example, from 0.1 to 0.5 centimeters or from 0.2 to 1.5 centimeters in thickness. 
     According to some embodiments of the present invention, the first protective layer  12  may comprise thermoplastic material enabling molding, such as injection plastic molding, techniques to be utilized. The first protective layer  12  may comprise acrylonitrile butadiene styrene (ABS), polycarbonate, glass, paraaramid synthetic fibers, such as Kevlar®, and carbon fiber composite, or thermosetting polymers. According to various embodiments, these materials alone or, e.g., in addition to metals and/or pieces of metals can be used for the accessory mount portion  10  as well. According to an embodiment of the present invention, the first protective layer  12  may comprise material based on paper pulp or other biodegradable materials, such as wood, paper laminates or pulp pressed, or solid wood. 
     According to an embodiment of the present invention, the first protective layer  12  may comprise at least one accessory mount portion  10  to which an accessory mount, such as of a camera or flashlight, may be arranged. The at least one accessory mount portion  10  may be integrally arranged as a part of the first protective layer  12 . The helmet may, preferably, also comprise an inner protective layer  14 , which typically is soft and able to absorb at least part of the energy of the impact. 
     According to an embodiment of the present invention, one accessory mount or one accessory may be arranged to several accessory mount portions  10  such that, e.g., one of several supports of the accessory mount or the accessory resides to one accessory mount portion  10 . 
     According to an embodiment of the present invention, the at least one accessory mount portion  10  may comprise titanium, aluminum, and/or carbon fiber. The strength of the at least one accessory mount portion may be affected by altering the thickness of the at least one accessory mount portion  10 . According to an embodiment, the at least one accessory mount portion  10  may be thermoplastic which may be strengthened with fibers, e.g. glass fibers. 
     According to an embodiment of the present invention, the at least one accessory mount portion  10  may have a shape such as round, oval, ellipse, square, rectangular or any other shape. According to an embodiment of the present invention, the diameter, or an average diameter, of the at least one accessory mount portion  10  may be, for example, less than 3.0, 5.0 or 7.0 centimeters. 
     There may, according to various embodiments of the present invention, also be a second protective layer  13  arranged between the first protective layer  12  and the inner protective layer  14 . The second protective layer  13  may be deformable and thus capable of significantly absorb the energy of the impact by deformation. The second protective layer  13  may comprise, for example, polystyrene or polypropylene. The second protective layer  13 , if any, may be, for example, from 1.0 to 2.0 or from 1.5 to 5.0 centimeters in thickness. 
     According to an embodiment of the present invention, the helmet  100  may comprise at least one weakening portion  16  which is configured to break in response to a mechanical impact to the at least one accessory mount portion  10  for disintegrating the at least one accessory mount portion  10  from the rest of the first protective layer  12 . 
     According to various embodiments of the present invention, the mechanical impact to the at least one accessory mount portion  10  may be a direct mechanical impact. It may also be an indirect mechanical impact through an accessory mount base  30 , an accessory mount or an accessory  50 , or in many cases through several of the three mentioned elements to the at least one accessory mount portion  10 . 
     According to various embodiments of the present invention, the at least one accessory mount portion  10  may be adapted to have larger outer surface than the inner surface. The outer surface refers herein to the surface facing the surroundings of the helmet and on which side the accessory, when mounted, is disposed. In typical conditions, the outer surface receives the mechanical impact. The inner surface refers herein to the inside volume of the helmet, i.e. the surface facing the user&#39;s head when the helmet is being worn by a user in normal manner. The inner surface thus faces an opposite direction with respect to the outer surface. According to a preferable embodiment, the at least one accessory mount portion  10  has a shape of a truncated cone with larger surface on the outer surface of the helmet  100 . The shape described herein prevents the at least one accessory mount portion from penetrating the helmet through the opening which is formed after disintegration of the at least one accessory mount portion  10  from the rest of the first protective layer  12 . 
     According to an embodiment of the present invention, the at least one weakening portion  16  may comprise a thinner part, such as a groove, cause by shape of the mold, in case of utilizing molding techniques for producing the first protective layer  12 . According to an embodiment of the present invention, the weakening portion  16  may be made by varying the thickness of the material used in the first protective layer  12 , or by laser treatment, or by manufacturing the weakening portion  12  as a separate part which is then attached to the first protective layer  12 . According to another embodiment of the present invention, mechanical engraving, heat treatment, or chemical etching may be used for producing the at least one weakening portion  16 . 
       FIG. 2  illustrates schematically a helmet  100  according to an embodiment of the present invention. The helmet  100  may comprise at least one protective element  20  arranged to a corresponding position or positions relative to the at least one accessory mount portion  10 . The purpose of the at least on protective element  20  is to prevent or at least try to prevent the at least one accessory mount portion  10  from penetrating the helmet  100  in case of a mechanical impact to the at least one accessory mount portion  10 . Said protective element  20  may, preferably, be arranged directly under the at least one accessory mount portion  10 , ‘under’ referring herein to a position between the at least one accessory mount portion and the user&#39;s head when the helmet is used in a normal manner for protecting the user&#39;s head such as shown in  FIG. 2 . 
     There may, preferably, be, as shown in  FIG. 2 , a space  22  arranged between the accessory mount portion  10  and the protective element  20 . The space  22  will further facilitate the disintegration of the at least one accessory mount portion  10  in response to a mechanical impact to the said mount portion  10  by allowing said mount portion  10  to slightly move thus breaking and disintegrating from the rest of the first protective layer  12  more easily. 
       FIG. 3  illustrates schematically a helmet  100  according to an embodiment of the present invention. The helmet  100  may comprise at least one protective element  20  arranged to corresponding positions relative to the at least one accessory mount portion  10 , in this case, two accessory mount portions  10 . The protective element  20  in this case is a band-type element but it may also be a plate- or disk-type. The protective element  20  may be straight or may have a convex or concave shape. The purpose of the at least on protective element  20  is to prevent or at least try to prevent the at least one accessory mount portion  10  from penetrating the helmet  100 . According to the specific embodiment illustrated in  FIG. 3 , the at least one protective element  20  is a band which extends to prevent or at least to try to prevent either one or both of two accessory mount portions  10  from penetrating the helmet  100 . The protective element  20  may also cover the user&#39;s head from objects  32 , such as an electronics component or for example a magnet, arranged between the first protective layer  12  and the protective element  20 . 
     According to an embodiment of the present invention, the helmet  100  may comprise an accessory mount base  30  as shown in  FIGS. 3 and 4 . The accessory mount base  30  may be utilized to attach an accessory mount or directly an accessory, such as a camera  50 . The accessory mount base  30  may be a general type of mounting base or a specific mounting base for a specific type of accessory  50 . According to an embodiment of the present invention, the accessory mount base  30  may be an integral part of the at least one accessory mount portion  10 . According to another embodiment of the present invention, the accessory mount base may be attached removable to the least one accessory mount portion  10 . According to an embodiment of the present invention, the accessory mount base  30  may be, e.g., a screw, bolt or pin. According to an embodiment of the present invention, the accessory mount base  30  may comprise a screw thread, a bayonet mount, a slide and click-mount, bend and click-mount, double-sided tape, or a rail/rails. 
       FIG. 5  illustrates schematically a helmet  100  according to an embodiment of the present invention comprising an accessory mount portion  10 , an accessory mount base  30  or an accessory mount, and a protective element  20  arranged in a corresponding position relative to the accessory mount portion  10 . 
     According to an embodiment of the present invention, in  FIGS. 6A and 6B , the at least one accessory mount portion  10  may consist of same or different material than the first protective layer  12 .  FIGS. 6A and 6B , as well as  FIGS. 7A-11B , illustrate embodiments of the present invention as cutaway and section views of the accessory mount portion  10  and/or the weakening portion  16 . According to an embodiment of the present invention, the material of the at least one accessory mount portion  10  may be able to withstand without breaking a lower mechanical impact with respect to the material of the first protective layer  12 . Thus by a choice of suitable materials, such as metal or ABS for the first protective layer  12  and thermoplastics, polyurethane or certain composites which withstand lower impact without breaking, for example, composites not having glass, carbon or Kevlar® fibers, for the at least one accessory mount portion  10 , said accessory mount portion  10  may be configured to disintegrate from the rest of the first protective layer  12  in response to a mechanical impact to the accessory mount portion  10 . Therefore the mechanical impact which the at least one accessory mount portion  10  withstands without breaking, and thus disintegrating from the rest of the first protective layer  12 , may be configured to have a pre-determined level depending on the chosen material of the accessory mount portion  10 . 
       FIGS. 7A-7C  illustrate, according to an embodiment of the present invention, the at least one weakening portion  16  that may comprise a groove. The groove may be arranged on the inner or the outer surface of the first protective layer  12 . 
     According to an embodiment of the present invention, the at least one weakening portion  16  comprising one weakening element or several weakening elements arranged corresponding positions with respect to one accessory mount portion  10 . This is illustrated in  FIGS. 7A and 7B . In  FIG. 7A , there is one weakening element comprising a groove, but could be a hole, perforation, piece of different material than the first protective layer  12 , which surrounds the respective at least one accessory mount portion  10 . In response to a mechanical impact to the at least one accessory mount portion  10 , the accessory mount portion would disintegrate along the one weakening element  16 . According to an embodiment of the present invention shown in  FIG. 7B , the at least one weakening portion comprises several weakening elements  16 , i.e., four grooves, surrounding the at least one accessory mount portion  10 .  FIG. 7C  illustrate a cross section view of the at least one weakening portion taken essentially perpendicular with respect to the at least one accessory mount portion  10 . 
       FIGS. 8A-8B  illustrate, according to an embodiment of the present invention, the at least one weakening portion  16  comprising a perforation. The perforation  16  may be arranged to extend through the first protective layer  12 . At least one of the plurality of holes  16  composing the perforation may extend through the first protective layer  12 . 
       FIGS. 9A-9B  illustrate, according to an embodiment of the present invention, the at least one weakening portion  16  comprises a plurality of holes  16 . At least one of the plurality of holes  16  may have a depth in the direction of the thickness of the first protective layer  12  less than the thickness of the first protective layer  12 . The at least one of the plurality of holes  16  may be arranged on the inner or the outer surface of the first protective layer  12 . 
       FIGS. 10A-10B  illustrate, according to an embodiment of the present invention, the at least one weakening portion  16  consisting of a material withstanding without breaking a lower mechanical impact with respect to the material of the first protective layer  12 . According to an embodiment, the at least one weakening portion  16  may consist of the same or a different material than the at least one accessory mount portion  10 . The at least one weakening portion  16  may comprise material such as polyurethane, composites with different characteristics, such as durability or strength, than material of the first protective layer  12  or the accessory mount portion  10 , e.g. a composite not having glass, carbon, or Kevlar fibers at the weakening portion  16 . According to an embodiment of the present invention, the at least one weakening portion  16  may comprise elastomers. 
       FIGS. 11A-11B  illustrate, according to an embodiment of the present invention, the at least one weakening portion  16 , such as a groove, a hole, or piece of the at least weakening portion consisting of a material withstanding without breaking a lower mechanical impact with respect to the material of the first protective layer  12 , is arranged such that the at least one weakening portion  16  may be arranged extend through the first protective layer or to have a width in the direction of the thickness of the first protective layer less than the thickness of the first protective layer  12 . The at least one weakening portion  16  may be arranged closer to the inner than the outer surface of the first protective layer  12 , or vice versa. 
       FIG. 12  illustrates, at  1200 , a flow diagram of a method for manufacturing a helmet according an embodiment of the present invention. 
     Item  1210  refers to a start-up phase of the method. Suitable materials, systems and machinery are obtained for manufacturing a helmet. 
     At  1220 , a first protective layer  12  in being obtained. A suitably formed or shaped layer may be obtained or the first protective layer may be done by, for example, molding thermoplastic material to a suitable form. 
     At  1230 , at least one accessory mount portion is being integrally arranged to the first protective layer. The at least one accessory mount portion is configured to disintegrate from the rest of the first protective layer in response to a mechanical impact to the at least one accessory mount. The at least one accessory mount portion may be same or different material than the first protective layer. The method step  1230  may be performed substantially simultaneously with the step  1220  if, for example, molding, such as injection plastic molding, techniques are used. 
     Method execution is ended at  1240  at which the helmet  100  comprising at least one accessory mount portion has been manufactured. 
     The specific examples provided in the description given above should not be construed as limiting the applicability and/or the interpretation of the appended claims. Lists and groups of examples provided in the description given above are not exhaustive unless otherwise explicitly stated.