RIGID HOLLOW PROTECTION CASING

Abstract

The rigid hollow protection casing (30) includes a first rigid layer (10) composed of a matrix of a first thermoplastic material (11) including in its interior at least one long-fibre fabric layer (12) selected from fibreglass, carbon fibre and/or aramid fibre and comprising between 45% and 65% of the total weight of the first layer (10); a second overlapping rigid layer (20) exterior to the first layer (10), the second layer (20) being entirely composed of a matrix thereof or of a second thermoplastic material (21), the second layer (20) comprising between 2% and 10% of the total weight of the casing (30).

Claims

1. A rigid hollow protection casing comprising: a first rigid layer composed of a matrix of a first thermoplastic material; and a second overlapping rigid layer exterior to the first layer, composed of a matrix of a second thermoplastic material, said matrix of first thermoplastic material includes at least one layer of long-fibre fabrics embedded in its interior, said long fibres are selected from fibreglass, carbon fibre and/or aramid fibre and comprise between 45% and 65% in total weight of the first layer; the second layer coats completely one exterior side of the first layer, comprises between 2% and 10% of the total weight of the casing and is entirely composed of said second thermoplastic material lacking long-fibre fabrics, providing a smooth finish to the casing.

2. The rigid hollow casing according to claim 1, wherein the first thermoplastic material is polypropylene, polyethylene, polyethylene terephthalate or polyamide and the second thermoplastic material is polypropylene, polyethylene, polyethylene terephthalate or polyamide.

3. The rigid hollow casing according to claim 1, wherein the first thermoplastic material and the second thermoplastic material are plastic materials with different melting points.

4. The rigid hollow casing according to claim 1, wherein the first thermoplastic material and the second thermoplastic material are the same plastic material.

5. The rigid hollow casing according to claim 1, wherein the long-fibre fabrics are unwoven fabrics.

6. The rigid hollow casing according to claim 1, wherein the long-fibre fabrics are woven fabrics.

7. The rigid hollow casing according to claim 1, wherein the long fibres are sized.

8. The rigid hollow casing according to claim 1, wherein the first thermoplastic material and/or the second thermoplastic material comprise graphene particles or fibres.

9. The rigid hollow casing according to claim 1, wherein the at least one long-fibre fabric layer is centred relative to the thickness of the first layer, having an identical coating thickness of the first thermoplastic material on both sides.

10. The rigid hollow casing according to claim 1, wherein the first layer comprises additional reinforcement areas with a number of long-fibre fabric layers greater than the rest of the first layer.

11. The rigid hollow casing according to claim 10, wherein the casing is a helmet shell in the shape of a hollow body with an access opening for the insertion of the user's head inside the shell and a visor opening, and the additional reinforcement areas comprise areas of the shell around the visor opening and areas around the access opening.

12. The rigid hollow casing according to claim 1, wherein the casing is selected from: a helmet shell with an access opening for the insertion of the user's head and with a visor opening a body armour, knee pads, elbow pads, wrist protectors, shoulder pads or other personal protection equipment boots and skates suitcases vehicle, aircraft or watercraft components racquets bicycle frames skis and snowboards surfboards, wakeboards and other aquatic sports wind turbine components.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The above and other advantages and features will be more completely understood from the following detailed description of an exemplary embodiment with reference to the attached drawings, which must be interpreted in an illustrative and non-limiting manner, in which:

[0040] FIG. 1 shows a perspective view of an exemplary embodiment of the proposed casing that, in this example, is a helmet shell;

[0041] FIG. 2 shows a perspective view of a detail of the composition of the proposed casing, wherein different elements are shown that constitute said casing, according to a preferred exemplary embodiment.

[0042] FIG. 3 shows a perspective view of a roller-skating boot incorporating the proposed casing.

[0043] FIG. 4 corresponds to an equivalent perspective view of ice-skating boot incorporating the proposed casing.

[0044] FIG. 5 shows a suitcase including in its walls the proposed casing.

DETAILED DESCRIPTION OF AN EXEMPLARY EMBODIMENT

[0045] The attached figures show in an illustrative, non-limiting manner exemplary embodiments of the present invention, consisting of a rigid hollow protection casing 30.

[0046] FIG. 1 shows a first exemplary embodiment according to which casing 30 is a helmet which include a shell provided with an access opening 31, intended for the insertion of the user's head within the shell, and a visor opening 32, intended so that the user has good visibility therethrough.

[0047] FIGS. 3 and 4 shows other alternative embodiments according to which the casing 30 is a roller skate boot or an ice skate boot which include a shell provided with an access opening 31, intended for the insertion of the user's foot within the shell, said shell surrounding and protecting the foot. Some parts of the boot will be made of other materials such textile materials.

[0048] FIG. 5 shows another alternative embodiment according to which the casing 30 is a shell constitutive of a suitcase.

[0049] Other embodiments of the proposed rigid hollow casing that are also contemplated, although not shown in the attached figures, are boots, ankle braces, knee pads, elbow pads, wrist protectors, body armours or even cases or covers.

[0050] In the case of the casing 30 being a shell of a helmet, both the access opening 31 and the visor opening 32 usually have a smaller size than the maximum dimension of the hollow interior of the shell, so that the manufacturing of said shell requires complex exterior moulds and interior moulds that are also complex that allow for their expansion and/or inflatable interior moulds.

[0051] The same happens with other previously cited applications of the casing 30, in which the access opening to its hollow interior is smaller than the maximum interior dimension, also requiring complex moulds for its manufacturing.

[0052] The material which conforms said casing 30 consists of a first layer 10 composed of a matrix of a first thermoplastic material 11 consisting in doped polypropylene (with additives to improve its resistance to impact and ultraviolet radiation and to improve its fluidity in the molten state).

[0053] Included in said matrix of the first thermoplastic material 11, there is at least one layer 12 of fabric of woven long fibres, forming strips of fabric such as those shown in FIG. 2.

[0054] The fabric strips are distributed covering all of the surface of the casing 30 with at least one layer of said fabric. In some reinforcing areas, several overlapping layers of fabric are included to increase the resistance of said reinforcing areas. In the case that the casing 30 is a shell, said reinforcing areas will correspond with at least the periphery of the access opening 31 and of the visor opening 32, while in other applications of the casing 30 said reinforcing areas will also correspond in adjacent areas of any opening they contain.

[0055] The total weight of the reinforcing long fibres 12 will represent at least 45% of the weight of the first layer, and at most 65%, the rest of the weight corresponding to the first thermoplastic material 11.

[0056] The fabric formed by said long fibres 12 will be centred with respect to the thickness of the first layer 10, that is, it will have a coating of a first thermoplastic material 11 of equal or similar thickness on both sides.

[0057] In another embodiment, not shown, the long fibres 12 are arranged in the shape of an unwoven fabric, randomly intertwined, thereby achieving an effect similar to that obtained with the woven fibres.

[0058] The presence of the long fibres 12 embedded in the first thermoplastic material 11 can produce flaws in the surface finish of the first layer 10 of the shell; so, it is proposed to include a second layer 20 of exterior coating integrally composed of a matrix of a second thermoplastic material 21, which in the present example it is proposed that it also be polypropylene, lacking reinforcing fibres, the second layer representing at most 10% in weight of the total of the shell and at least 2%.

[0059] A second embodiment will be identical to the first embodiment but replacing the first material 10 or the second material 20 by a polyethylene, which will have a lower melting point than the polypropylene.

[0060] A third proposed embodiment will also be identical to the first embodiment but using polyethylene as the first material and the second material, both requiring a lower melting point.

[0061] Alternatively, it is contemplated that polypropylene may be used as the first material and polyethylene terephthalate as the second material or use polyethylene terephthalate both as the first material and as the second material.

[0062] According to another embodiment, one or both materials can be polyamides.

[0063] Additionally, it is contemplated that both the first thermoplastic material and the second one 11, 21 may include a low percentage of graphene particles or fibres as an additive that increase the resistance of the shell.

[0064] Regardless of the product used as first and second thermoplastic materials 11, 21, it will be convenient that both materials have a different melting point, which can be achieved with additives or with the selection of said materials. This allows a more controlled manufacturing process and an improved integration of the layers.

[0065] It will be understood that different parts that constitute the invention described in an embodiment may be freely combined with the parts described in other different embodiments although such a combination has not been explicitly described, as long as no detriment exists in the combination.

[0066] Any of the items explained can be manufactured by defining the casing of the same in a mold inside which is included an inflatable bag that presses against the inner wall of the casing. In addition, means of heating of the mould or the arrangement of the mould assembly with the inflatable bag inside a heating oven are provided.