Patent Description:
<CIT>) relates to a protective helmet with multiple energy management liners.

The present invention relates to a cycling helmet in accordance with claim <NUM>.

Other principal features and advantages of the invention will become apparent to those skilled in the art upon review of the following drawings, the detailed description, and the appended claims.

Illustrative embodiments will hereafter be described with reference to the accompanying drawings, wherein like numerals denote like elements. The foregoing and other features of the present disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several embodiments in accordance with the disclosure and are, therefore, not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through use of the accompanying drawings.

Traditional cycling helmets often utilize a stiff foam material, such as EPS, to absorb all of the impact in the event of an accident. The impact absorbed by the helmet during an accident can include both direct impact and rotational or oblique impact. During a direct impact in which the helmet contacts an object straight on, the EPS can often effectively absorb the contact and prevent injury to the user due to the (irreversible) compressibility of the EPS. However, during a rotational/oblique impact in which the helmet slides along, rolls along, or glances off an object, traditional EPS helmets are sometimes unable to fully absorb the impact, resulting in a higher likelihood of injury. One reason for the higher likelihood of injury during a rotational impact is that traditional EPS inserts are statically mounted within a shell and are unable to move with the user's head during such impact. As a result, the user's head movement is restricted during an accident, and it is possible that axons in the brain can stretch and/or tear during the rotational/oblique impact.

Described herein is a cycling helmet that utilizes an insert made from energy absorbing material with multi-directional flexibility. The energy absorbing material, which can be made from polycarbonate or a similar material, is able to bend, compress, stretch, and shift in multiple directions without shearing. As discussed herein, the energy absorbing material is maintained in a largely spherical shape within a shell of the helmet such that the material retains its ability to bend, compress, stretch, and shift in multiple directions.

<FIG> depicts a front view of a cycling helmet <NUM> in accordance with an illustrative embodiment. <FIG> depicts a rear view of the cycling helmet <NUM> in accordance with an illustrative embodiment, and <FIG> depicts a side view of the cycling helmet <NUM> in accordance with an illustrative embodiment. As depicted, the cycling helmet <NUM> includes an outer shell <NUM> and a closed cell foam layer <NUM> that is surrounded by the outer shell <NUM>. As depicted in <FIG>, the cycling helmet <NUM> also includes a fit system <NUM> that includes a yoke <NUM> and straps <NUM> for securing the cycling helmet <NUM> to a user's head. The fit system <NUM> is described in more detail below with reference to <FIG>.

The outer shell <NUM> of the cycling helmet <NUM> can be made from plastic, resin, fiber, polycarbonate, polyethylene, terephthalate (PET), acrylonitrile butadiene styrene, polyethylene (PE), polyvinyl chloride (PVC), vinyl nitrile (VN), fiberglass, carbon fiber, or other similar material. In addition to housing other components of the cycling helmet <NUM>, the outer shell <NUM> provides a rigid outer layer. Depending on the implementation, the outer shell <NUM> can be formed through stamping, molding, vacuum forming, or any other known fabrication technique. The outer shell <NUM> is formed to include vent openings that form vents <NUM>. The vents <NUM> are included to improve airflow, increase breathability, and reduce the overall weight of the cycling helmet <NUM>.

Adjacent to the outer shell <NUM> is the closed cell foam layer <NUM>. In an illustrative embodiment, an inner surface of the outer shell <NUM> is coated with an adhesive that is used to attach the closed cell foam layer <NUM> to the outer shell <NUM>. Any type of suitable adhesive may be used. The closed cell foam layer <NUM> can be formed by blowing, molding, or any other technique known to those of skill in the art. In another illustrative embodiment, the closed cell foam layer <NUM> can be made of expanded polystyrene (EPS). In alternative embodiments, the closed cell foam layer <NUM> can be made of one or more layers of the same or similar materials, including an impact energy absorbing material such as expanded polypropylene (EPP), expanded polyurethane (EPU), vinyl nitrile (VN), or any other material that absorbs impact energy through deformation. The closed cell foam layer <NUM> also includes vent openings that are aligned with the vent openings in the outer shell <NUM> to form the vents <NUM>. In an illustrative embodiment, the vent openings on the interior side of the closed cell foam layer <NUM> are chamfered to allow an energy absorbing insert in the cycling helmet to move relative to the vent openings without being restricted by them. The chamfered edges of the closed cell foam layer <NUM> are depicted and described in more detail with reference to <FIG>.

The straps <NUM> of the cycling helmet <NUM> are used to secure the cycling helmet <NUM> to a user's head. Any type of adjustable helmet strap may be used. In an illustrative embodiment, the straps <NUM> include a first strap attached a left side of the cycling helmet <NUM> and a second strap attached to the right side of the cycling helmet <NUM>. The first strap and second strap are configured to be connected to one another under a user's chin by way of a buckle or clip as known to those of skill in the art. In an illustrative embodiment, the straps <NUM> are integrated into the fit system <NUM> that includes the yoke <NUM> and other components. In an alternative embodiment, the straps <NUM> may be independent of the yoke <NUM>. The fit system <NUM> and its components are described in more detail below.

<FIG> is a front cross-sectional view of a cycling helmet <NUM> in accordance with an illustrative embodiment. <FIG> is a side cross-sectional view of the cycling helmet <NUM> in accordance with an illustrative embodiment. In addition to the outer shell <NUM> and the closed cell foam layer <NUM>, <FIG> depict an insert <NUM> of energy absorbing material. In an illustrative embodiment, the insert <NUM> can be formed of plastic, resin, fiber, polycarbonate, polyethylene, terephthalate (PET), acrylonitrile butadiene styrene, polyethylene (PE), polyvinyl chloride (PVC), vinyl nitrile (VN), fiberglass, carbon fiber, aluminum, or other similar material. The insert <NUM> can be a solid material, or can have a honeycomb configuration with openings to help facilitate deformation. In an illustrative embodiment, the insert <NUM> is elastically or plasticly deformable and is able to bend, compress, stretch, and shift in multiple directions without shearing.

The insert <NUM> of energy absorbing material is maintained within a largely spherical shape within the cycling helmet <NUM> such that the insert <NUM> covers at least a portion of the top, front, and rear of a user's head. <FIG> is a front perspective view of an insert <NUM> of energy absorbing material in accordance with an illustrative embodiment. <FIG> is a front cross-sectional view of the insert <NUM> in accordance with an illustrative embodiment, and <FIG> is a side cross-sectional view of the insert <NUM> in accordance with an illustrative embodiment. In alternative embodiments, the insert may be of a different shape and/or configuration. For example, in one embodiment, the insert may be formed to cover only a top and front (i.e., forehead) of the user's head. In such an embodiment, a thicker closed cell foam layer can be used in the back of the cycling helmet to cover the back of the user's head and to create a uniform contour within the cycling helmet to fit the user's head.

Referring again to <FIG>, the insert <NUM> is adjacent to an inner liner <NUM> which acts as a surface to support the insert <NUM>. The inner liner <NUM>, which is rigid, also provides additional stability and strength to the cycling helmet <NUM>. The inner liner <NUM> can be formed from polycarbonate or any other suitable material such as carbon, aluminum, etc. In an illustrative embodiment, the inner liner <NUM> is molded into the cycling helmet <NUM> and an outer surface of the inner liner <NUM> is fused to the closed cell foam layer <NUM> using an adhesive. Similar to the outer shell <NUM> and the closed cell foam layer <NUM>, the inner liner <NUM> also includes aligned vent openings to form the vents <NUM> described with reference to <FIG>. The inner liner <NUM> can also include chamfering along the vent openings which aligns with and covers the chamfered edges on the vent openings in the closed cell foam layer <NUM>.

An inner side of the inner liner <NUM> includes an inner liner coating. In an illustrative embodiment, the inner liner coating is a paint that provides a low friction (or slippery) surface for the insert <NUM> to rest upon. In an alternative embodiment, the inner liner coating may be a powder coat or other low friction substance other than paint. The low friction surface of the inner liner coating enables the insert <NUM> of energy absorbing material to bend, compress, stretch, and/or otherwise shift in the event of an impact to the cycling helmet <NUM>. Chamfered edges on the vent openings of the inner liner <NUM> also help facilitate the movement of the insert <NUM> such that binding of the insert <NUM> does not occur at the vent openings. In an alternative embodiment, not forming part of the claimed invention, in which the inner liner <NUM> is formed from a low friction material, the inner liner coating may not be used.

As depicted in <FIG>, the closed cell foam layer <NUM> forms a shelf <NUM> that is configured to support a bottom edge of the insert <NUM>. The shelf <NUM> helps prevent removal of the insert <NUM> and also acts as a support that maintains the insert <NUM> in a largely spherical shape within the cycling helmet <NUM>. During an impact, the shelf <NUM> acts as a stop that helps to prevent the insert <NUM> from sliding out of the cycling helmet <NUM>.

Depending on the type of material used for the insert <NUM> of energy absorbing material, the interior edges of the insert <NUM> may be somewhat abrasive and uncomfortable if in direct contact with skin. An insert cover <NUM> is used to cover a portion of the inner edge of the insert <NUM> that is adjacent to the shelf <NUM>. More specifically, the insert cover <NUM> covers a portion of the closed cell foam layer <NUM> that is adjacent to the shelf <NUM> and a portion of an interior surface of the insert <NUM>. In an illustrative embodiment, the insert cover <NUM> traverses the entire interior perimeter of the cycling helmet <NUM> to add comfort and protect the user's head from an abrasive surface that may be found on the insert <NUM>. In addition to adding comfort, the insert cover <NUM> also helps keep the insert <NUM> in place and helps prevent its removal.

In an illustrative embodiment, the insert cover <NUM> is formed from polycarbonate. Alternatively, the insert cover <NUM> may be made of a different material. In another illustrative embodiment, the insert cover <NUM> can be attached to the fit system <NUM> and can be mounted to the cycling helmet <NUM> by way of anchors that are attached to the closed cell foam layer <NUM> using mushroom plugs. This configuration is depicted and described in more detail with reference to <FIG>. In an alternative embodiment, an adhesive can be used to mount the insert cover <NUM> to the insert <NUM> and to a portion of the closed cell foam layer <NUM> adjacent to the shelf <NUM>. In another alternative embodiment, the insert cover <NUM> may not be attached to the fit system <NUM>.

As depicted in <FIG>, the insert cover <NUM> covers only a small portion of the inner surface (or edge) of the insert <NUM> of energy absorbing material. In one embodiment, an insert coating can be used to cover the remainder of the inner surface of the insert <NUM> to add comfort and protect the user from the potentially abrasive surface. In an illustrative embodiment, during manufacturing, the inner surface of the insert <NUM> may be cut with a hot wire cutter. Depending on the type of material used for the insert <NUM>, the use of a hot wire cutter can result in the formation of plastic beads along the inner surface of the insert <NUM>. The plastic beads formed on the inner surface of the insert <NUM> are able to accept beads of paint which form the insert coating. Once cured, the paint of the insert coating provides a more comfortable surface to the touch and against a user's head. In an alternative embodiment, such an insert coating may not be used.

In an illustrative embodiment, the insert cover <NUM> depicted in <FIG> is mounted to the fit system <NUM> described with reference to <FIG>. <FIG> is a top view of an insert cover <NUM> mounted to a fit system <NUM> in accordance with an illustrative embodiment. <FIG> is a side view of the insert cover <NUM> mounted to the fit system <NUM> in accordance with an illustrative embodiment. <FIG> is a cross-sectional side view of the insert cover <NUM> and the fit system <NUM> incorporated into a cycling helmet <NUM> in accordance with an illustrative embodiment. <FIG> is a cross-sectional front view of the insert cover <NUM> and the fit system <NUM> incorporated into the cycling helmet <NUM> in accordance with an illustrative embodiment. It is noted that in <FIG> and <FIG> that the insert is not depicted for clarity. <FIG> is a front view of the insert cover <NUM> in accordance with an illustrative embodiment. <FIG> is a side view of the insert cover <NUM> in accordance with an illustrative embodiment. <FIG> is a rear view of the insert cover <NUM> in accordance with an illustrative embodiment. <FIG> is a top view of the insert cover <NUM> in accordance with an illustrative embodiment. <FIG> is a perspective view of the insert cover <NUM> in accordance with an illustrative embodiment. <FIG> is a front view of a yoke <NUM> of the fit system <NUM> in accordance with an illustrative embodiment. <FIG> is a rear view of the yoke <NUM> of the fit system <NUM> in accordance with an illustrative embodiment.

As depicted in <FIG>, the insert cover <NUM> is mounted to four anchors <NUM> which in turn are molded or otherwise incorporated into a closed cell foam layer <NUM>. In alternative embodiments, fewer or additional anchors may be used. In one embodiment, the insert cover <NUM> is mounted to the anchors <NUM> by way of mushroom plugs <NUM> that traverse holes <NUM> in the insert cover <NUM> and the anchors <NUM>. In alternative embodiments, any other type of fastener or attachment method may be used to mount the insert cover <NUM> to the anchors <NUM>. The insert, which is not depicted in <FIG>, can include openings that allow the mushroom plugs <NUM> or other fasteners to pass from the insert cover <NUM> to the anchors <NUM> which are incorporated into the closed cell foam layer <NUM>. For example, the openings <NUM> depicted in the insert <NUM> of <FIG> and <FIG> can be used to allow the mushroom plugs <NUM> to pass from the insert cover <NUM> to the anchors <NUM>.

<FIG> depicts an anchor <NUM> in accordance with an illustrative embodiment. A rear framework <NUM> of the anchor <NUM> is incorporated into the closed cell foam layer of a cycling helmet such that the closed cell foam layer securely holds the anchor <NUM> in place. A mounting surface <NUM> of the anchor <NUM> faces an interior of the cycling helmet when the anchor <NUM> is mounted. The mounting surface <NUM> includes openings <NUM> that are configured to receive one end of mushroom plugs or other fasteners. The other ends of the mushroom plugs are mounted to an insert cover as discussed with reference to <FIG>. In an illustrative embodiment, when mounted, the mounting surface <NUM> of the anchor <NUM> is flush with an interior surface of the closed cell foam layer. In such an implementation, the mushroom plugs (or other fasteners) extend from the insert cover, through openings in the insert and into the openings <NUM> of the mounting surface <NUM>. In an alternative embodiment, the mounting surface <NUM> of the anchor <NUM>, when mounted, may be flush with an interior surface of the insert. In such an embodiment, the insert includes an opening configured to receive the mounting surface <NUM>.

Referring again to <FIG>, it can be seen that the fit system <NUM> includes a yoke <NUM>. The yoke <NUM> includes a ratchet device <NUM> that is used to tighten and loosen cables <NUM> which are attached to a head strap <NUM> such that the user can obtain a comfortable and secure fit of the cycling helmet on his/her head. The head strap <NUM>, which is configured to surround at least a portion of the perimeter of the user's head, may include padding for added comfort. A mounting strap <NUM> of the yoke <NUM> is used to mount the yoke <NUM> to the insert cover <NUM>. In an illustrative embodiment, the mounting strap <NUM> is slidably mounted to a receiving strap <NUM> of the insert cover <NUM> such that the yoke <NUM> can be raised and lowered relative to the user's head. The mounting strap <NUM> of the yoke <NUM> can be mounted to the insert cover <NUM> using a mushroom plug or any other type of fastener known to those of skill in the art.

As discussed above, the cycling helmet can include straps, such as the straps <NUM> depicted in <FIG>, that are configured to go under a user's chin to help secure the cycling helmet to the user's head. In an illustrative embodiment, these straps <NUM> can be secured to the fit system <NUM>. In an alternative embodiment, the straps <NUM> may be independently mounted to the cycling helmet. For example, each of the first strap and the second strap can have two anchor points such that the strap is secured to the closed cell foam layer at four locations. In one embodiment, one of the two anchor points of the first strap is positioned in front of the user's ear when the cycling helmet is worn and the other anchor point is positioned behind the user's ear. Similarly, the two anchor points of the second strap can also be positioned in front of and behind the user's opposite ear when the cycling helmet is worn. Such an embodiment is depicted in <FIG>.

<FIG> is a partial perspective view of an anchoring location for a strap in accordance with an illustrative embodiment. The anchoring location for the strap is positioned within a closed cell foam layer <NUM>. As discussed above, the closed cell foam layer <NUM> includes a shelf <NUM> that is configured to support a bottom edge of an insert of energy absorbing material. The shelf <NUM> includes a shelf opening <NUM> configured to receive and anchor a terminal end of the strap. The shelf opening <NUM> can be formed in the closed cell foam layer <NUM>. The strap travels down through the shelf opening <NUM> and out through a side opening <NUM> in the closed cell foam layer <NUM> such that the strap is accessible to a user.

<FIG> is a partial cross-sectional view of the anchoring location in <FIG> in accordance with an illustrative embodiment. The anchoring location includes a first passage <NUM> which is adjacent to the shelf <NUM> and the shelf opening <NUM>. The anchoring location also includes a second passage <NUM> which is adjacent to the side opening <NUM>. As indicated in <FIG>, the first passage <NUM> is wider than the second passage <NUM>. This difference in width enables anchoring of a strap as depicted in <FIG> is a partial cross-sectional view of the anchoring location with a strap <NUM> in accordance with an illustrative embodiment. The strap <NUM> has a loop <NUM> at its terminal end, and a bar <NUM> is inserted into the loop <NUM>. The bar <NUM> is able to fit into the first passage <NUM>, but is unable fit within the second passage <NUM>. As a result, the bar <NUM> and thus the strap <NUM> are anchored at the interface between the first passage <NUM> and the second passage <NUM>. The bar <NUM> can be metallic or plastic, depending on the implementation.

<FIG> is a partial sectional view depicting the interface between an insert <NUM> and a vent <NUM> of a cycling helmet in accordance with an illustrative embodiment. The vent <NUM> is formed as an opening in both an outer shell <NUM> and a closed cell foam layer <NUM> of the cycling helmet. An interior surface of the closed cell foam layer <NUM> is chamfered to form a chamfered edge <NUM> along the internal perimeter of the vent <NUM>. The chamfered edge <NUM> allows the insert <NUM> to move freely relative to the vent <NUM> without binding in the event of an impact to the cycling helmet. Also depicted in <FIG> is an interface between an insert cover <NUM>, the insert <NUM>, and the closed cell foam layer <NUM>. The interface is formed such that the insert cover <NUM> is inset into and flush with both the insert <NUM> and the closed cell foam layer <NUM>. As a result, comfort is improved because the insert cover <NUM> does not stick out past the insert <NUM> or the closed cell foam layer <NUM>.

<FIG> is a flow diagram depicting operations performed to construct a cycling helmet in accordance with an illustrative embodiment. In alternative embodiments, fewer, additional, and/or different operations may be performed. Additionally, the use of a flow diagram is not meant to be limiting with respect to the order of operations performed. In an operation <NUM>, an outer shell is formed for the cycling helmet. In an illustrative embodiment, the outer shell is formed from a sheet of polycarbonate, which is heated and pressure formed around an outer shell mold. Vent openings are then placed into the pressure formed outer shell using a hot knife cutting process. In alternative embodiments, different materials and/or a different process may be used to form the outer shell.

In an operation <NUM>, an inner liner for the cycling helmet is formed. In an illustrative embodiment, the inner liner is formed as a thin layer of a rigid substance such as polycarbonate. Alternatively, other materials may be used. Similar to the outer shell, the inner liner may be formed by heating and pressure molding a sheet of material into the appropriate shape, and then cutting vent openings into the molded unit. In another illustrative embodiment, the vent openings of the inner liner can have a chamfered edge that matches the chamfered edges of the vent openings formed in the closed cell foam layer. In alternative embodiments, different materials and/or a different process may be used to form the inner liner.

In an operation <NUM>, an inner liner coating is applied to an inner surface of the inner liner. The inner liner coating can be a paint that provides a low friction (or slippery) surface for the insert to rest upon. Alternatively, the inner liner coating may be a powder coat or other low friction substance. The low friction surface of the inner liner coating helps allow the insert of energy absorbing material to bend, compress, stretch, and/or shift in the event of an impact. In an alternative embodiment, not forming part of the claimed invention, in which a surface of the inner liner is sufficiently slippery on its own, an inner liner coating may not be applied. In one embodiment, the inner liner coating may be applied to the material used to form the inner liner prior to the actual formation of the inner liner.

In an operation <NUM>, a closed cell foam layer is mounted between the outer shell and the inner liner. In an illustrative embodiment, the closed cell foam layer can be made from pre-expanded EPS that is co-molded (or injection molded) with the outer shell and the inner liner in a mold. In such an implementation, the closed cell foam layer is formed and mounted to the cycling element during the injection molding process. In an alternative embodiment, the closed cell foam layer may be formed independent of the outer shell and the inner liner. In such an embodiment, the closed cell foam layer is mounted to the cycling helmet using an adhesive, fasteners, and/or any other techniques. In alternative embodiments, a different material and/or fabrication process may be used. In another illustrative embodiment, the closed cell foam layer is molded to include a shelf to support an insert, vent openings, and a chamfered edge that surrounds the vent openings along the interior surface of the layer. The closed cell foam layer can also be molded such that anchors are incorporated therein to receive a fit system and an insert cover as described herein. The closed cell foam layer can further be molded to include an inset to receive a portion of the insert cover such that the insert cover can be mounted flush with the interior surface of the closed cell foam layer.

In an operation <NUM>, an insert for the cycling helmet is formed. The insert can be formed by molding, cutting from a sheet of material, or by any other fabrication process known in the art. In an illustrative embodiment, the insert can be made of plastic, resin, fiber, polycarbonate, polyethylene, terephthalate (PET), acrylonitrile butadiene styrene, polyethylene (PE), polyvinyl chloride (PVC), vinyl nitrile (VN), fiberglass, carbon fiber, aluminum, or any other suitable material. As discussed above, the insert is able to bend, compress, stretch, and shift in multiple directions without shearing. The insert can be a solid material, or in the form of a honeycomb with openings that facilitate the bending, compression, stretching, and/or shifting of the material. Formation of the insert can also include incorporating openings in the insert through which mushroom plugs or other fasteners can be passed to secure the insert cover to the anchors molded into the closed cell foam layer. Formation of the insert can also include forming an inset in an interior surface of the insert that is configured to receive a portion of an insert cover. In an illustrative embodiment, the insert is formed such that it does not include vent openings such as those present in the outer shell and the closed cell foam layer. In an alternative embodiment, the insert may be formed to include such vent openings which align with those in the outer shell and the closed cell foam layer.

In an operation <NUM>, the insert is placed into the cycling helmet. In an illustrative embodiment, the insert is positioned such that the insert is adjacent to and follows the contour of coated inner liner. The insert is also positioned such that a bottom edge of the insert rests upon the shelf formed in the closed cell foam layer, as described herein.

In an operation <NUM>, an insert cover is mounted to the closed cell foam layer such that the insert cover covers an interior interface between the insert and the shelf formed in the closed cell foam layer. In an illustrative embodiment, the insert cover is mounted such that it is received by insets formed in both the closed cell foam layer and the insert. As a result, the mounted insert cover is flush with both the insert and the closed cell foam layer along the aforementioned interior interface between those components. The insert cover can be mounted via mushroom plugs or other fasteners which connect the insert cover to the anchors molded into the closed cell foam layer.

In an operation <NUM>, a yoke of a fit system is mounted to the insert cover using mushroom plugs or other fasteners. In an illustrative embodiment, the yoke includes a mounting strap that is configured to be received by a receiving strap attached to the insert cover. In alternative embodiments, a different method for mounting the fit system to the cycling helmet may be used.

The word "illustrative" is used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as "illustrative" is not necessarily to be construed as preferred or advantageous over other aspects or designs. Further, for the purposes of this disclosure and unless otherwise specified, "a" or "an" means "one or more".

Claim 1:
A cycling helmet (<NUM>, <NUM>, <NUM>) comprising:
an outer shell (<NUM>, <NUM>);
a closed cell foam layer (<NUM>, <NUM>, <NUM>, <NUM>) adjacent to the outer shell;
an inner liner (<NUM>) adjacent to the closed cell foam layer;
an insert of energy absorbing material (<NUM>, <NUM>) adjacent to the inner liner, wherein the insert is configured to move in multiple directions in response to an impact to the cycling helmet; and characterized by
an inner liner coating positioned on the inner liner (<NUM>) such that the inner liner coating is adjacent to an outer surface of the insert, wherein the inner liner coating comprises a low friction coating.