US20260013592A1

US20260013592A1 - Protective helmet

Info

Publication number: US20260013592A1
Application number: US19/264,452
Authority: US
Inventors: Pier Franco UZZENI
Original assignee: U Power Group SpA
Current assignee: U Power Group SpA
Priority date: 2024-07-10
Filing date: 2025-07-09
Publication date: 2026-01-15
Also published as: EP4678051A1

Abstract

A protective helmet comprising a shell, a crown comprising a ring-shaped body, and a cage for the head of a user, configured to be internally attached to the shell, wherein the crown is interposed between the shell and the cage when the cage is attached to the shell.

Description

TECHNICAL FIELD

The present invention relates to the sector of protective helmets for work or sports use.

PRIOR ART

As is known, protective helmets are used in various fields, both at work and in sports. Protective helmets are normally used by workers who perform activities in environments where there is a potential risk of the head of the worker being exposed to knocks or impacts (for example, building site workers, firefighters, etc.). Protective helmets are also used in a sporting environment for example by cyclists, skiers, hikers or rock climbers.
A protective helmet typically comprises a cap which forms the protective shell provided by the helmet in the event of knocks or impacts resulting from external objects. The shell may be closed or open. In this latter case it typically comprises openings for allowing ventilation.
Furthermore, depending on the conditions of use, it is known to use the protective helmet with accessories, such as a sunshade, a protective visor for the face, anti-noise earmuffs, a torch or a front lamp, reflective elements, a rear protection, for example made of fireproof material, etc.
The patent application IT102022000023316 in the name of the same Applicant describes a shell for a protective helmet comprising a shell body and a functional band around at least a front part and/or a rear part of the shell body, wherein the functional band comprises a central wall, an upper wall and a lower wall, wherein the functional band comprises a seat for attachment of an accessory, formed by an opening in the upper wall, in the lower wall, or in the upper wall and lower wall of the functional band.

SUMMARY OF THE INVENTION

The Applicant has defined the aim of improving the protective helmets, for example the protective helmet described in IT102022000023316, from the point of the view of their robustness.
The Applicant has noted that the protective helmets according to the present state of the art may be improved in terms of their resistance to impacts which occur at the height of the user's head, in particular in the frontal region, occipital region and temporal regions.
In view of the above, the Applicant has defined the aim of providing a protective helmet which ensures a greater robustness with regard to impacts which occur at the height of the frontal region, occipital region and temporal regions of the user's head.
According to a first aspect, the present invention provides a protective helmet comprising:

- a shell;
- a crown comprising a ring-shaped body; and
- a cage for a user's head, configured to be internally attached to the shell;
- wherein the crown is interposed between the shell and the cage when the cage is attached to the shell.

According to embodiments of the invention, the shell comprises a shell body comprising, on its internal surface, at least two attachment slots for attaching the cage to the shell.
According to these embodiments, the protective element further comprises attachment elements for attaching the cage to the shell by means of engagement with the at least two attachment slots.
According to embodiments of the invention, the crown comprises, on both an internal surface and an external surface of the ring-shaped body, a number of cavities and grooves.
According to embodiments of the invention, the crown comprises, on its upper edge, four protuberances, the protuberances being located, when the helmet is worn by a user, in the frontal region, the occipital region and the temporal regions of the user's head.
According to embodiments of the invention, the crown is made of sintered expanded polystyrene.
According to embodiments of the invention. the cage comprises a plurality of openings and at least two arms, each of the arms comprising an end portion with a hole and a vertical tooth configured to engage with a respective slot of the attachment slots when the cage is attached to the shell.
According to embodiments of the invention, each of the attachment elements comprises a ring portion, comprising a hole, and two elastic prongs which extend from the ring portion and each of which terminates in a respective retaining tooth.
According to embodiments of the invention, the protective helmet comprises, internally, on an upper portion of the shell body, an internal protection element.
According to embodiments of the invention, the protective helmet comprises an empty space between a top of the cage and the internal protection element, the empty space having a vertical dimension greater than 25 mm.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become clearer from the following detailed description, provided purely by way of a non-limiting example, to be read with reference to the accompanying figures in which:

FIG. 1 is an exploded view of a protective helmet according to an embodiment of the present invention;

FIG. 2 is another axonometric view of the helmet according to FIG. 1 ;

FIGS. 3 a and 3 b are two views of a shell of the helmet;

FIGS. 4 a and 4 b are two views of a crown of the helmet;

FIGS. 5 a and 5 b are two views of a cage of the helmet;

FIG. 6 shows an attachment element for the helmet;

FIG. 7 is a cross-sectional view of the helmet; and

FIG. 8 is another cross-sectional view of the helmet.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

According to the present invention, a protective helmet which comprises a shell, a crown and a cage is provided. The crown is interposed between the shell and the cage. According to embodiments of the invention, the crown is kept in position by means of mechanical interlocking, as will be described in greater detail below.
FIGS. 1 and 2 show a protective helmet 1 (also referred to simply as “helmet”) according to embodiments of the present invention. As shown in the Figures, the helmet 1 comprises a shell 2, a crown 3, a cage 4 for the user's head, and a number of attachment elements. In particular, according to the embodiment of the helmet shown in the Figures, the helmet 1 comprises four attachment elements 5 a, 5 b, 5 c, 5 d. When the helmet 1 is assembled, the crown 3, which is a ring-shaped element, is located interposed in an interlocking manner between the shell 2 and the cage 4, which is internally attached to the shell 2 by means of the attachment elements. The cage 4 is a support structure for the user's head, configured to rest on the head of the user of the helmet 1 when the helmet is worn.
The helmet 1 may also comprise other elements, a detailed description of which is not relevant for the purposes of the present invention. These elements comprise: afront support band for the user's forehead, which may also assume different positions in order to improve the comfort; a support element below the back of the neck associated with a size adjustment device which may also assume different positions owing to a roller wheel mechanism and an adjustable guide; and a strap for fastening the helmet under the chin, which comprises a snap-engaging buckle.
The shell 2 comprises a shell body 21. It may also comprise a closing piece 22 and a functional band 23. In the embodiments in which said functional band is present, it is of the type described in IT102022000023316.
According to these embodiments, the functional band 23 comprises a first portion fixed to the front part of the shell body and a second portion fixed to the rear part of the shell body. The two portions of the band which are situated in the front part and rear part of the shell both have an elongated arch shape. According to these embodiments, these two portions of the band are made as parts separate from the body of the shell and then fixed thereto. They may for example be fixed in a surface recess formed in the body of the shell. The band is preferably completed by two side portions which are situated on both sides of the shell body: in particular they are portions of the shell body projecting outwards so that the thickness of said side portions corresponds substantially to the thickness of the front and rear portions of the band.
More particularly, as shown in FIG. 3 a or 3 b, the functional band 23 preferably comprises a first band portion 23 a positioned in the front part of the shell, a second band position 23 b positioned in the rear part of the shell; the band 23 further comprises a first side band portion 23 c and a second side band portion 23 d along a left-hand side part of the shell 2 and right-hand side part of the shell 2, respectively, which are preferably integral with the shell body 21, namely formed as a single body therewith.
The shell body 21 is shaped so as to receive at least partially the head of a user of the helmet. Once the shell is worn by the user, the front part of the shell 2, and therefore the first band portion 23 a, is situated in the frontal region of the user's head, while the rear part of the shell 2, and therefore the second band portion 23 b, is situated in the occipital region of the user's head; the first side portion 3 c of the functional band 3 and the second side portion 3 d of the functional band 3 are instead situated in the temporal regions, i.e. respectively, opposite the left-hand ear and the right-hand ear of the user.
According to these embodiments, the shell body 21 (which comprises the side portions 23 c and 23 d of the functional band 23), the first band portion 23 a and the second band portion 23 b are made as separate parts. The first band portion 23 a and the second band portion 23 b are preferably made of a substantially rigid thermoplastic material, for example polypropylene or ABS (acrylonitrile butadiene styrene). The first band portion 23 a and the second band portion 23 b have preferably a thickness of between 2 mm and 10 mm, more preferably between 2 mm and 5 mm, and a width, in the region of a central wall, preferably of between 10 mm and 30 mm. The shell body 21 is also preferably made of a substantially rigid thermoplastic material, for example polypropylene or ABS (acrylonitrile butadiene styrene).
According to these embodiments, the first band portion 23 a and the second band portion 23 b are preferably fixed to the shell body 21. Fixing may be performed by means of suitable fixing means, such as screws or pins, and/or by means of gluing and/or welding. For example, the first band portion 23 a and the second band portion 23 b may comprise, on an internal surface thereof, a number of pins suitable for engaging inside corresponding holes formed in the shell body 21, for example in the region of the recess configured to house the corresponding band portion.
The shell body 21 has a convex internal surface and a convex external surface with a shaped bottom edge. The shaping of the bottom edge is performed so to adapt the helmet to the user's head, in particular, for example, in the zones corresponding to the position of the user's ears so as to accommodate anti-noise earmuffs which may be fixed to the shell 2.
The shell body 21 may have, on its external surface, a number of ribs which define zones of varying thickness of the said shell body. For example, as schematically shown in FIG. 3 a , the external surface of the shell body 21 comprises ribs 24 which, in particular, define a projecting portion on the top part of the shell body 21, so as to provide protection from impacts occurring from above.
Along the first lateral band portion 23 c, the external surface 21 of the shell body 21 shown in the Figures is preferably shaped so as to allow fixing of a first earmuff of a pair of anti-noise earmuffs to the shell 2. In particular, the external surface 22 of the shell body 21 preferably has a raised portion 25 a for housing underneath it the top part of the earmuff. In the thickness of the shell body 21 along this raised portion 25 a there is present a through-slot 26 a which opens out underneath the raised portion 25 a of the shell body 21 internally with respect thereto. Similarly, along the second side band portion 23 d, the external surface 22 of the shell body 21 is preferably shaped so as to allow fixing of the second earmuff of the pair of anti-noise earmuffs to the shell 2. In particular, the external surface 21 of the shell body 2 preferably has a raised portion 25 b for housing underneath it the top part of the earmuff. In the thickness of the shell body 21 along this raised portion 25 b there is present a through-slot 26 b which opens out underneath the raised portion 25 a of the shell body 21 internally with respect thereto.
As mentioned above, fixing of a pair of anti-noise earmuffs to the shell 1 is performed by means of known fixing means present on the muffs, which engage with the through-slots 26 a and 26 b. The anti-noise earmuffs are known components of a protective helmet and for this reason will not be described here in detail.
FIG. 3 b shows in particular the inside of the shell 2. In the zone where, externally, the functional band 23 is present, the internal surface of the shell has a band portion 27 which extends over the entire perimeter of the shell 2 and has a pair of recesses 25 a′, 25 b′ corresponding to the raised portions 25 a and 25 b which in turn are located along the side portions 23 c, 23 d of the functional band 23. As can been seen in FIG. 3 b , the side walls of each recess 25 a′, 25′ each have a through-opening which allows the ends of the first portion and the second portion of the functional band 23 to be passed through and attached when said portions of the functional band 23 are applied to the shell body 21.
Along the band portion 27 there are present, in a number of predefined positions, at least two attachment slots for attaching the cage 4 to the shell 2 by means of the attachment elements, as will be described in greater detail below. In the shell 2 according to the embodiment shown in the Figures there are present four slots 28 a, 28 b, 28 c, 28 d positioned in pairs on the two sides of the shell body 21. In particular, the two slots of each pair are positioned on the sides of a respective recess 25 a′, 25 b′ of the shell body 21 at a certain distance from the side walls of said recess.
The attachment slots are hence located in the proximity of the shaped bottom edge of the shell body 21. Moreover, as can be seen in FIG. 3 b , the shell body 21 has, on its top part, in particular on the aforementioned projecting portion delimited by the ribs 24, a number of holes 29 formed in the thickness of the shell body 21 (in FIG. 3 b these holes are shown by way of example as having a square/rectangular shape and are aligned along two parallel longitudinal directions). These holes may be used to provide ventilation for the helmet 1. Internally, along the projecting portion, the shell body 21 shown in the Figures has a grid of internal ribs 211.
The closing piece 22 may be mounted with an interlocking fit onto the shell body 21, externally, on the projecting portion. When mounted on the shell body 21, the closing piece 22 closes off externally the holes 29. The closing piece 22 is made of nylon for example.
The shell 2, finally, may optionally comprise an internal protection element (also called “stopper”)—not shown in the Figures—which is shaped so as to be housed in the shell 2 on the inside of the top portion of the shell body 21. In the embodiment shown in the figures, the stopper is housed opposite the grid of internal ribs 211. This element may provide further protection for the user's head. It is, for example, made of polystyrene, in particular EPS (sintered expanded polystyrene), so to absorb effectively any knocks and impacts. This element may also comprise a series of through-holes in order to favour ventilation.
An example of a crown for the protective element according to the present invention is shown schematically in FIGS. 4 and 4 b and indicated by the reference number 3. The crown is preferably made of a plastic material, in particular polystyrene. More in particular, the crown may be made of EPS. The density of the material of the crown is for example within the range of between 50 kg/m³and 100 kg/m³.
The crown 3 is preferably made in the form of a single ring-shaped body. It comprises, both on the internal surface and on the external surface, a number of cavities and grooves which are provided which the aim of adapting the shape of the crown itself to that of the two components between which it is inserted, namely the shell body 21 and the cage 4, and so as not to interfere with the operation of other elements, such as the size adjustment device. Moreover, the form of the crown 3 has the purpose of allowing air to pass inside the shell 2 so as to ensure ventilation around the user's head. For this purpose, some of the cavities and grooves of the crown 3 are located in positions corresponding to those of some openings formed in the thickness of the cage 4 so that, once the helmet 1 is assembled, the passage of air towards the user's head is ensured. Finally, the presence of cavities and grooves in the crown 3 allows its weight to be lightened, while ensuring the necessary impact resistance properties.
In particular, the crown 3 shown schematically in the Figures comprises a ring-shaped body 31 with an upper edge 31 a and a lower edge 31 b. Moreover, the body 31 comprises a number of protuberances which project from its upper edge. In particular, for example, the crown 3 comprises four protuberances each located in a specific region of the user's head, namely in the frontal region, the occipital region and the temporal regions. The position of the crown 3 may be understood more clearly by considering also FIGS. 7 and 8 which show two different cross-sections through the helmet 1. The four protuberances are indicated in the Figures by the reference numbers 32 a, 32 b, 32 c and 32 d. These protuberances advantageously increase the impact resistance of the helmet in the regions indicated.
A first protuberance 32 a is located in the frontal region. The body 31, along the first protuberance 32 a, in the embodiment shown in the Figures, comprises two cavities 321, 322 on the external surface (namely on the surface which, once the helmet is assembled, faces the internal surface of the shell 2) and a cavity 323 on the internal surface. These cavities are open along the top edge of the body of the crown 3 and have a concave shape tapered towards the bottom edge.
A second protuberance 32 b is located in the occipital region. The body 31, along the second protuberance 32 b, in the embodiment shown in the Figures, comprises a through-groove 324 on its internal surface. Said through-groove, in addition to ensuring the ventilation in the occipital region, is able to house an adjustable guide of the device for adjusting the size of the helmet 1.
A third protuberance 32 c and a fourth protuberance 32 d are located in the temporal regions. In each of them, the body 31 comprises, on the external surface, a cavity 325 which is open on the bottom edge and has a concave shape tapered towards the top edge. Moreover, the body 31, on its internal surface, comprises one or more cavities 326 which are open on the top edge.
The ring-shaped body 31 shown schematically in FIGS. 4 a and 4 b comprises other grooves and cavities, which will not be further described in detail.
FIGS. 5 a and 5 b show the cage 4 in greater detail. The cage 4 is preferably made of a thermoplastic polymer, for example a synthetic polyamide such as nylon or PA66. The material of the cage 4 is advantageously associated with high mechanical resistance and thermal stability. It is configured to rest on the user's head when the helmet 1 is worn. Optionally, on the internal surface, the cage may be associated with a lining element having a padding and anti-perspiration function. This element may be associated with the cage by means of hook-and-loop closing systems, such as Velcro®. This element is not shown in the Figures.
The cage 4 has a convex shaped form configured to adapt to the inside of the shell 2. The cage 4 has an internal surface and an external surface and comprises a plurality of through-openings 41 formed in its thickness and having different—mainly elongated—shapes. These openings have the function of favouring the ventilation inside the helmet 1 and lightening its weight. In order to favour the ventilation, the openings in the cage 4 are mainly configured to be positioned, when the helmet 1 is assembled, opposite the grooves and cavities of the crown 3, so as to define through-channels for the air. The cage 4 comprises other elements, on its external surface, which allow the assembly of the helmet, such as pins 42 for the attachment of the terminal portion of the arms of the size adjustment device and for attachment of the front band. Moreover, the cage 4 shown in the Figures comprises, internally, on its rear portion, a channel 43 for sliding of the adjustable guide of the size adjustment device.
According to embodiments of the present invention, the cage 4 comprises at least two arms for fixing the cage itself to the shell body. In particular, according to the embodiment shown in FIGS. 5 a and 5 b , the cage 4 has four arms 44 a, 44 b, 44 c, 44 d which extend substantially from the top of the cage 4 and terminate in respective end portions 45 a, 45 b, 45 c, 45 d. Each end portion extends from the respective arm substantially horizontally outwards and comprises a respective hole 46 a, 46 b, 46 c, 46 d. Each hole 46 a, 46 b, 46 c, 46 d has preferably a rectangular shape. Moreover, on the outer edge of each end portion there is present a respective vertical tooth 47 a, 47 b, 47 c, 47 d which extends upwards.
The area of each end portion 45 a, 45 b, 45 c, 45 d corresponds substantially to the transverse area of a respective slot 28 a, 28 b, 28 c, 28 d present on the internal surface of the shell body 21. In this way, during assembly of the helmet 1, in order to fix the cage 4 to the shell body 21, the cage 4 is inserted inside the shell body 21 by aligning the arms 44 a, 44 b, 44 c, 44 d with the positions of the four slots 28 a, 28 b, 28 c, 28 d. Each end portion 45 a, 45 b, 45 c, 45 d is brought into contact with a respective slot 28 a, 28 b, 28 c, 28 d so that the end portion 45 a, 45 b, 45 c, 45 c is located underneath the slot and in contact with the said slot such that the hole 46 a, 46 b, 46 c, 46 d of the end portion is located aligned with the hole of the slot and the vertical tooth 47 a, 47 b, 47 c, 47 d enters into the hole of the slot 28 a, 28 b, 28 c, 28 d. Fixing is performed by inserting into the two aligned holes an attachment element, as will be discussed in greater detail hereinbelow.
The cage 4 has preferably a thickness comprised between 1 mm and 5 mm.
FIG. 6 shows in schematic form one of the attachment elements, indicated by the reference number 5. Each attachment element 5 comprises preferably a ring portion 51 comprising an elongated hole with a substantially rectangular shape. Two elastic prongs 52 extend from one of the long sides of the ring portion 51, each of them terminating in a retaining tooth 53. The dimension of the long side of the ring portion 51 is greater than the dimension of the hole present in the end portion of the arm of the cage 4. When the helmet 1 is assembled, each attachment element is inserted inside a respective through-opening formed when the end portion of an arm of the cage is aligned and brought into contact with the slot present inside the shell body. The through-opening is formed by the hole of the end portion and the cavity of the slot. In particular, the attachment element is moved towards the through-opening and the prongs are moved towards each other and inserted into the said hole so that they then emerge at the top and the edge of the ring portion abuts against the edge of the hole of the end portion of the arm. In this way, each arm of the cage 4 is stably fixed to the shell body 21 and the cage 4 is kept in position inside the shell body 21. The ring portion 51 projects underneath the end portion of the arm, as shown in FIGS. 2, 7 and 8 . The hole of each ring portion may be used to allow the insertion of the strap for fastening the helmet underneath the chin. The retaining tooth 53 present at the end of each of the prongs 52 has the function of preventing the attachment element from coming out of the through-opening formed by the hole in the end portion and by the slot in the shell body. Should the attachment element move downwards, the retaining tooth comes into abutment against the edge of the slot and prevents the attachment element itself from coming out through the through-opening in which it s inserted.
It should be noted that attachment of the cage 4 to the shell body 21 may also be performed differently.
In order to assemble the protective helmet shown in the Figures, the crown 3 is inserted inside the shell body 21 so that the protuberances 32 a, 32 b, 32 c, 32 d described above are positioned in the front, rear and side parts of the helmet so as to protect the frontal, occipital and temporal regions of the user's head. The cage 4 is then inserted inside the shell body 21 and fixed inside the shell body 21, for example as described above. In this way, the crown 3 remains interlocked between the shell body 21 and the cage 4. As can be seen from FIGS. 7 and 8 , the helmet 1 comprises an empty space between the top of the cage 4 and the internal surface of the shell body 21 in the top part of the helmet. In particular, the components of the helmet 1 are designed so that the vertical dimension of this empty space (hence the distance between the top of the cage 4 and the internal surface of the shell body 21 or any internal protection element of the shell) is greater than 25 mm.
When the helmet 1 is assembled, the crown 3 is interposed between the internal surface of the shell body 21 and the external surface of the cage 4. In particular, the crown 3 is at least partially in contact with the internal surface of the shell body 21 and the external surface of the cage 4.
It should be noted that the presence of the crown has both a structural function and a ventilation function in the helmet according to the present invention. The crown in fact, for all intents and purposes, is a helmet reinforcing element which is able to limit the effects of impacts in the event of deformation of the shell. The crown also provides reinforcement in the region of the arms of the cage, i.e. in the positions where the cage is fixed to the shell body. Moreover, both the internal and external grooves and cavities of the crown are able to ensure the ventilation inside the helmet, ensuring that there is an air flow between the different zones of the helmet.
From a structural point of view, the assembly of the helmet is particularly simple and effective. It consists in fact of an assembly system which is entirely of an interlocking nature and therefore does not require external element such as screws. In particular, as already described above, the cage is fixed by means of attaching slots inside the shell body, in the proximity of the bottom edge, which can be realized in a more convenient way than other types of fixing elements, such as pins or other male elements. Contrary to pins, which may project towards the inside of the shell body and could be dangerous in case of knocks or impacts, the attachment slots are a simpler and safer attachment arrangement.

Claims

1. A protective helmet comprising:

a shell;

a crown comprising a ring-shaped body; and

a cage for a user's head, configured to be internally attached to said shell,

wherein said crown is interposed between said shell and said cage when said cage is attached to said shell,

wherein the shell comprises a shell body comprising, on its internal surface, at least two attachment slots for attaching the cage to the shell.

2. The protective helmet according to claim 1, further comprising attachment elements for attaching the cage to the shell by means of engagement with said at least two attachment slots.

3. The protective helmet according to claim 1, wherein said crown comprises, on both an internal surface and an external surface of the ring-shaped body, a number of cavities and grooves.

4. The protective helmet according to claim 1, wherein said crown comprises, on its upper edge, four protuberances, said protuberances being located, when the helmet is worn by a user, in the frontal region, the occipital region and the temporal regions of the user's head.

5. The protective helmet according to claim 1, wherein said crown is made of sintered expanded polystyrene.

6. The protective helmet according to claim 1, wherein the cage comprises a plurality of openings and at least two arms, each of said arms comprising an end portion with a hole and a vertical tooth configured to engage with a respective slot of said attachment slots when the cage is attached to the shell.

7. The protective helmet according to claim 2, wherein each of said attachment elements comprises a ring portion, comprising a hole, and two elastic prongs which extend from said ring portion and each of which ends in a respective retaining tooth.

8. The protective helmet according to claim 1, comprising internally, in an upper portion of the shell body, an internal protection element.

9. The protective helmet according to claim 8, comprising an empty space between a top of the cage and said internal protection element, said empty space having a vertical dimension greater than 25 mm.