Protective helmet with multi-density impact liners and method for same

• US 10,010,127 B1
• Filed: 06/29/2017
• Issued: 07/03/2018
• Est. Priority Date: 06/29/2017
• Status: Active Grant

• Current Assignee: Bell Sports Incorporated (Easton-Bell Sports Incorporated)
• Original Assignee: Bell Sports Incorporated (Easton-Bell Sports Incorporated)
• Inventors: Shaffer, Samuel J., Penner, Benjamin W.
• Primary Examiner(s): Hurley, Shaun R
• Assistant Examiner(s): Nguyen, Bao-Thieu L
• Application Number:
  US15/638,217
• Time in Patent Office: 369 Days
• Field of Search: 2411, 2412, 2424, 2425
• CPC Class Codes: A42B 3/125 with a padded structure, e.g. foam
• CPC Class Codes: A42B 3/128 with zones of different density
• CPC Class Codes: A42C 2/002 In-mould forming
• CPC Class Codes: B29C 44/08 using several expanding or moulding steps
• CPC Class Codes: B29C 44/12 Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
• CPC Class Codes: B29C 44/3426 Heating by introducing steam in the mould
• CPC Class Codes: B29C 44/445 in the form of expandable granules, particles or beads
• CPC Class Codes: B29C 44/5681 Covering the foamed object with, e.g. a lining
• CPC Class Codes: B29C 44/569 Shaping and joining components with different densities or hardness
• CPC Class Codes: B29K 2023/12 PP, i.e. polypropylene
• CPC Class Codes: B29K 2025/06 PS, i.e. polystyrene
• CPC Class Codes: B29K 2069/00 Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/048 Expandable particles, beads or granules
• CPC Class Codes: B29K 2995/0063 Density
• CPC Class Codes: B29K 2995/0091 Damping, energy absorption
• CPC Class Codes: B29L 2031/4821 Helmets

Abstract

A helmet and method for forming a helmet having a multi-density impact liner may include forming a puck with an interface surface and at least one side. The interface surface of the puck is placed in direct contact with a receiving surface of a cap located in an impact liner mold. Next, the interface surface of the puck is thermally fused directly to the receiving surface of the cap while contemporaneously an impact liner body is formed inside the mold. The impact liner body is fused to the at least one side of the puck, and to a majority of the receiving surface of the cap. The density of the puck may be greater than the density of the impact liner body. The puck and the impact liner body may be EPS, and the cap may be PC.

Claims

1. A method for forming a helmet, the method comprising:

forming a puck having an interface surface and at least one side;

placing the interface surface of the puck in direct contact with a receiving surface of a cap located in an impact liner mold;

thermally fusing the interface surface of the puck directly to the receiving surface of the cap while contemporaneously forming an impact liner body inside the impact liner mold, the impact liner body fusing to the at least one side of the puck and to a majority of the receiving surface of the cap while being formed.

2. The method of claim 1, wherein the density of the puck is greater than the density of the impact liner body.

3. The method of claim 1, wherein the puck and the impact liner body comprise expanded polystyrene (EPS), and the cap comprises polycarbonate (PC).

4. The method of claim 3, wherein the density of the puck is greater than the density of the impact liner body, and wherein, proximate the at least one side fused to the impact liner body, the puck has a thickness substantially equal to a thickness of the impact liner body.

5. The method of claim 1 wherein the interface surface of the puck is in contiguous contact with the receiving surface of the cap.

6. The method of claim 1, wherein the puck is located proximate a front edge of the cap.

7. The method of claim 1, wherein at least one of the at least one sides of the puck is exposed adjacent to an edge of the cap after the impact liner body is formed.

8. The method of claim 1, wherein the receiving surface of the cap is an outer surface of a multi-liner rotation cap, the outer surface facing away from an interior of the helmet.

9. The method of claim 1, wherein the receiving surface of the cap is an inner surface of an external helmet cap, the inner surface facing toward an interior of the helmet.

10. A method for forming a helmet, the method comprising:

forming a puck comprising expanded polystyrene (EPS) having an interface surface and at least one side;

placing the interface surface of the puck in direct contact with a receiving surface of a cap located in an impact liner mold such that the puck is located proximate a front edge of the cap, the cap comprising polycarbonate (PC);

thermally fusing the interface surface of the puck directly to the receiving surface of the cap while contemporaneously forming an impact liner body inside the impact liner mold, the impact liner body fusing to the at least one side of the puck and to a majority of the receiving surface of the cap while being formed.

11. The method of claim 10, wherein the receiving surface of the cap is an outer surface of a multi-liner rotation cap, the outer surface facing away from an interior of the helmet.

12. The method of claim 10, wherein the receiving surface of the cap is an inner surface of an external helmet cap, the inner surface facing toward an interior of the helmet.

13. A helmet, comprising:

a cap having a receiving surface;

an impact liner body thermally fused to a majority of the receiving surface of the cap; and

a puck having an interface surface and at least one side, wherein the interface surface of the puck is thermally fused to the receiving surface of the cap, and at least one of the at least one sides of the puck is thermally fused to the impact liner body.

14. The helmet of claim 13, wherein the interface surface of the puck is in contiguous contact with the receiving surface of the cap.

15. The helmet of claim 13, wherein the puck has a density higher than a density of the impact liner body.

16. The helmet of claim 13, wherein the puck and the impact liner body comprise expanded polystyrene (EPS), and the cap comprises polycarbonate (PC).

17. The helmet of claim 13, wherein the puck is located proximate a front edge of the cap.

18. The helmet of claim 13, wherein at least one of the at least one sides of the puck is exposed.

19. The helmet of claim 13, wherein the receiving surface of the cap is an outer surface of a multi-liner rotation cap, the outer surface facing away from an interior of the helmet.

20. The helmet of claim 13, wherein the receiving surface of the cap is an inner surface of an external helmet cap, the inner surface facing toward an interior of the helmet.

21. The helmet of claim 13, wherein, proximate the at least one side directly coupled to the impact liner body, the puck has a thickness substantially equal to a thickness of the impact liner body.