SAFETY HELMET WITH A RESILIENTLY ATTACHED SHOCK-ABSORBING SHELL AND PROCESS FOR MANUFACTURING SAME

Abstract

A safety helmet (100) includes an arched helmet shell (2), an arched shock-absorbing shell (1), a holding ring (3, 11) and a resilient element (14). The holding ring (3, 11) is permanently connected to the helmet shell (2). The shock-absorbing shell (1) adjoins a holding ring edge. The resilient element (14) is supported at the holding ring (3, 11), projects over the holding ring edge and acts to move the shock-absorbing shell (1) away from the holding ring (3, 11) and to press shock-absorbing shell (1) against the helmet shell (2). A process for manufacturing such a safety helmet (100) is provided. According to the process, first the shock-absorbing shell (1) is placed first into the helmet shell (2) and the holding ring (3, 11) is then attached to the helmet shell (2).

Claims

1. A safety helmet comprising: an arched helmet shell encompassing an helmet shell interior area; a holding ring with a curved holding ring edge, the holding ring being located in the helmet shell interior area and permanently connected to the helmet shell; an arched shock-absorbing shell with a curved shock-absorbing shell edge, the shock-absorbing shell being located in the helmet shell interior area, adjoining the helmet shell and configured to absorb kinetic energy wherein the shock-absorbing shell edge areally adjoins the holding ring edge; and a resilient element located in the helmet shell interior area and supported at the holding ring, wherein the resilient element touches the shock-absorbing shell edge and is configured to move the shock-absorbing shell away from the holding ring and to press the shock-absorbing shell against the helmet shell.

2. A safety helmet in accordance with claim 1, wherein: the holding ring comprises a projection pointing towards the shock-absorbing shell; and the projection engages with a corresponding recess of the shock-absorbing shell.

3. A safety helmet in accordance with claim 2, wherein the projection is located between the helmet shell and the shock-absorbing shell.

4. A safety helmet in accordance with claim 1, wherein: the shock-absorbing shell comprises a projection pointing towards the helmet shell; and the helmet shell comprises a stop element pointing towards the shock-absorbing shell; the projection and the stop element together limit a movement of the shock-absorbing shell relative to the helmet shell in at least one direction.

5. A safety helmet in accordance with claim 1, wherein: the holding ring edge extends in a plane and has at least one adjoining protruding area, protruding from this plane, which at least one adjoining protruding area adjoins the shock-absorbing shell edge; and a profile of the at least one adjoining protruding area corresponds to a profile of an adjoining area of the shock-absorbing shell edge.

6. A safety helmet in accordance with claim 1, wherein: the shock-absorbing shell has an outwardly arched projection; the helmet shell has a groove; and the projection of the shock-absorbing shell engages with the groove of the helmet shell.

7. A safety helmet in accordance with claim 1, further comprising a bearing ring, wherein: the bearing ring encompasses the head of a user of the safety helmet and is in contact with the head of the user of the safety helmet in at least one area; and a distance is formed between the holding ring and the bearing ring.

8. A safety helmet in accordance with claim 7, wherein a circumferential dimension of the bearing ring is variable; and a distance is formed between the shock-absorbing shell and the bearing ring.

9. A process for manufacturing a safety helmet, the process comprising the steps of: providing an arched helmet shell encompassing a helmet shell interior area; providing an arched shock-absorbing shell with a curved shock-absorbing shell edge, the shock-absorbing shell being configured to absorb kinetic energy; providing a holding ring with a curved holding ring edge; providing at least one resilient element, which is supported at the holding ring; inserting the shock-absorbing shell into the helmet shell interior area such that the shock-absorbing shell is placed in the helmet shell; subsequent to the step of inserting the shock-absorbing shell, inserting the holding ring into the helmet shell such that the shock-absorbing shell edge areally adjoins the holding ring edge and the resilient element presses the shock-absorbing shell away from the holding ring and against the helmet shell; and permanently connecting the inserted holding ring to the helmet shell with the resilient element pressing the shock-absorbing shell against the helmet shell.

10. A process according to claim 9, further comprising providing a computer program, which is executable on a computer and causes the computer during the execution to actuate one or more 3D printers such that an actuated 3D printer produces at least one of the shock-absorbing shell, the holding ring and the resilient element.

11. A process according to claim 9, further comprising providing a 3D printer, which is configured to produce at least one of the shock-absorbing shell, the holding ring and the resilient element.

12. A process according to claim 11, further comprising: providing at least another 3D printer configured to produce at least one of the shock-absorbing shell, the holding ring and the resilient element; producing at least one of the shock-absorbing shell, the holding ring and the resilient element with the other 3D printer.

13. A process according to claim 12, wherein the 3D printer and the other 3D printer: are at different locations; or produce different components of the safety helmet; or are at different locations and produce different components of the safety helmet.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0051] In the drawings:

[0052] FIG. 1 is a perspective view showing the safety helmet from an oblique direction from below and from the side;

[0053] FIG. 2 is a perspective view showing the safety helmet from an oblique direction from below and from the rear;

[0054] FIG. 3 is a perspective view showing the safety helmet from an oblique direction from below and from the front ;

[0055] FIG. 4 is a perspective view showing the safety helmet from the viewing direction shown in FIG. 2, wherein the bearing rings are omitted;

[0056] FIG. 5 is a perspective view showing the safety helmet from the viewing direction shown in FIG. 3, wherein the bearing rings and additionally the additional visor are omitted;

[0057] FIG. 6 is a perspective view showing the safety helmet from FIG. 5, wherein the shock-absorbing shell is additionally omitted;

[0058] FIG. 7 is a side view showing the front holding ring part;

[0059] FIG. 8 is a perspective view showing the rear holding ring part from a first viewing direction;

[0060] FIG. 9 is a perspective view showing the rear holding ring part from FIG. 8 from a second viewing direction;

[0061] FIG. 10 is a perspective view showing a first embodiment of the shock-absorbing shell from the left in an oblique direction from the top;

[0062] FIG. 11 is a side view showing the shock-absorbing shell from FIG. 10;

[0063] FIG. 12 is a perspective view showing a second embodiment of the shock-absorbing shell from the inside;

[0064] FIG. 13 is a side view showing the shock-absorbing shell from FIG. 12;

[0065] FIG. 14 is a perspective view showing the helmet shell from the inside from a first viewing direction; and

[0066] FIG. 15 is a perspective view showing the helmet shell from the inside from a second viewing direction.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0067] Referring to the drawings, the present invention pertains to a safety helmet, which is used by firefighters, police, rescue workers and other rescue team members in order better to protect the head from mechanical, thermal and chemical effects.

[0068] The safety helmet according to the exemplary embodiment comprises - like many other safety helmets - an arched helmet shell made of a hard material, an arched shock-absorbing shell, a bearing structure and an inner lining. The inner lining is in contact with the head of a person, who is wearing this safety helmet on his head. This person will hereinafter be called “the user.” The bearing structure connects the inner lining to the helmet shell and is attached on the inside to the helmet shell. The inner lining is omitted in the figures.

[0069] The terms “front,” “rear,” “left,” “right,” “top” and “bottom” used below refer to the usual orientation when the user wears the safety helmet and is looking forward. The viewing direction BR of the user looking straight forward is shown in some figures.

[0070] The shock-absorbing shell is in contact on the inside with the helmet shell, it absorbs kinetic energy acting from the outside on the safety helmet and pads the safety helmet. The shock-absorbing shell shall be seated on the inside in the helmet shell without a major clearance. The present invention shows a way of achieving this effect without a connection by connection in substance having to be established between the helmet shell and the shock-absorbing shell, especially without a bonded connection and without a Velcro connection.

[0071] FIG. 1, FIG. 2 and FIG. 3 show a safety helmet 100, which has the following components, from different viewing directions:

[0072] an arched helmet shell 2 made of a hard material, an arched shock-absorbing shell 1, which is inserted on the inside into the helmet shell 2, a pivotable visor 4, [0073] a front holding ring part 3, which is detachably connected from the inside to the helmet shell 2, [0074] an additional visor in the form of sunglasses 26, which is arranged between the front holding ring part 3 and the helmet shell 2, [0075] a left screw connection 16.1 and a right screw connection 16.r in order to detachably connect the front holding ring part 2 to a respective functional plate on the outside at the helmet shell 2, wherein the two screw connections 16.1 and 16.r additionally hold the visor 4 pivotably at the helmet shell 2, [0076] a left screw connection 5.1 and a right screw connection 5.r, which hold the additional visor 26 at the front holding ring part 3, [0077] a front bearing ring part 6, which is in contact with the forehead of the user and is detachably connected to the front holding ring part 3, [0078] a two-part rear bearing ring part 7 with a left rear part 7.1 and with a right rear part 7.r, which is in contact with the back of the head of the user, [0079] a central rear bearing ring part 10 in the form of a bearing support for the back of the head, which bearing support is likewise in contact with the back of the head of the user and is connected to the two parts 7.1 and 7.r of the rear bearing ring part 7 by a respective snap-in connection, [0080] a left holding arm 8.1 and a right holding arm 8.r at the front holding ring part 3, [0081] a left holding arm 9.1 at the left part 7.1 of the rear bearing ring part 7, [0082] a right holding arm 9.r at the right part 7.r of the rear bearing ring part 7, [0083] a snap-in connection between the two left holding arms 8.1, 9.1, and [0084] a snap-in connection between the two right holding arms 8.r, 9.r.

[0085] The indices .1 and .r designate a left part and a right part, respectively.

[0086] The safety helmet 100 additionally comprises an inner lining with textile components, which come into contact with the scalp of a user. This inner lining is omitted in the figures.

[0087] The outer profile of the safety helmet 1 is adapted to the inner profile of the helmet shell 2.

[0088] The bearing ring parts 6, 7, 10 form a curved and annular bearing ring, which fully encircles the head of the user and can be adapted to the shape of the head of the user. The holding ring parts 3, 11 are connected permanently to the helmet shell 2 on the inside. A distance develops in one embodiment between the holding ring part 3 and the bearing ring part 6. An optional, permanent intermediate piece 27 bridges over this distance. In another embodiment, the bearing ring part 6 is attached directly, i.e., without an intermediate piece 27, to the holding ring part 3.

[0089] This bearing ring part 6, 7, 10 shall be seated, on the one hand, so firmly on the head of the user that the safety helmet 100 will not slip relative to the head, and, on the other hand, it shall not press the head of the user too strongly. The user can therefore change the length of the bearing ring 6, 7, 10 and hence the head size of the safety helmet 100 manually, doing so by means of a handwheel 15 in the rear at the safety helmet 100. A rotation of the handwheel 15 causes the two parts 7.1 and 7.r to be moved synchronously away from one another or synchronously toward one another.

[0090] The bearing ring parts 6, 7 and 10 as well as the brackets for these are omitted in

[0091] FIG. 4 and FIG. 5. As a result, a central rear holding ring part 11 will become fully visible, and the rear holding ring part 11 is arranged between the rear bearing rings 7 and 10 and the helmet shell 2 and is detachably connected to the helmet shell 2 and its outer profile is adapted to the inner profile of the helmet shell 2. The rear holding ring part 11 is preferably elastic in itself and presses the helmet shell 2 from the inside based on its own elasticity. The rear holding ring part 11 comprises two through holes 12.1, 12.r, through which the two screws 24.1, 24.r are passed. These screws 24.1, 24.r are screwed into two screw threads 25.1, 25.r on the inside in the helmet shell 2 and hold the rear holding ring part 11 from the inside at the helmet shell 2. A preferably resilient and preferably centrally arranged projection 14 presses the shock-absorbing shell 1 from below and presses hereby the shock-absorbing shell 1 upward against the helmet shell 2. This projection belongs to a resilient element in the sense of the claims.

[0092] In the perspective view shown in FIG. 6, the additional visor 26 and additionally the shock-absorbing shell 1 are omitted. Two lateral projections 13.1, 13.r are seen at the top at the rear holding ring part 11. These projections 13.1, 13.r are in contact with the helmet shell 2 from the inside and are located between the helmet shell 2 and the shock-absorbing shell 1. The shock-absorbing shell 1 has a downwards pointing edge. A considerable part of a front area of this edge lies at the top on the front holding ring part 3, and a rear area of this edge lies on the projection 14. The two projections 13.1, 13.r extend from the outside towards the shock-absorbing shell 1. As a result, the shock-absorbing shell 1 is held in its position relative to the helmet shell 2 without a connection by connection in substance being necessary. In particular, no bonded connection and no Velcro connection are needed.

[0093] FIG. 7 shows in a side view from the left the front holding ring part 3, which has, when viewed from the top, the shape of half of an ellipse. A front holding ring edge K.3, which points upwards and has an obliquely rising front part K.3v, can be seen. The front holding ring edge K.3 extends in a plane that is at right angles to the drawing plane of FIG. 7. The front part K.3v protrudes from this plane. The front part K.3v extends in the exemplary embodiment in another plane, which has an oblique orientation on the plane of the front holding ring edge K.3. This other plane is likewise at right angles to the drawing plane of FIG. 7.

[0094] FIG. 8 and FIG. 9 show in perspective views the rear holding ring part 11 from two different viewing directions, namely, once from the front (FIG. 8) and once from the rear (FIG. 9). An upwards pointing, rear holding ring edge K.11, which belongs to the rear holding ring part 11, can be seen. The front holding ring edge K.3 and the rear holding ring edge K.11 form together a curved holding ring edge. This curved holding ring edge K.3, K.11 points upwards in case of a usual application.

[0095] FIG. 10 and FIG. 11 show in two perspective views a first embodiment of the shock-absorbing shell 1. FIG. 12 and FIG. 13 show in two perspective views a second embodiment of the shock-absorbing shell 1. A shock-absorbing shell edge K.1, namely, one from the left (FIG. 11), from the inside (FIG. 12), and one on the left from the side (FIG. 13), can be seen. During a usual use of the safety helmet 100, this shock-absorbing shell edge K.1 points downward. When the shock-absorbing shell 1, the front holding ring part 3 and the rear holding ring part 11 are arranged in the interior of the helmet shell 7, the downwards pointing shock-absorbing shell edge K.1 of the shock-absorbing shell 1 is seated on the upwards pointing, front holding ring edge K.3 and on the upwards pointing, rear holding ring edge K.11. Furthermore, the following components of the shock-absorbing shell 1 can be seen: [0096] two laterally arranged recesses 17.1, 17.r at the downwards pointing shock-absorbing shell edge K.1, with which the two laterally arranged projections 13.1, 13.r at the rear holding ring part 11 engage, [0097] a centrally arranged recess 18 at the shock-absorbing shell edge K.1, with which the centrally arranged, resilient projection 14 at the rear holding ring part 11 engages, [0098] a front edge area 19 of the shock-absorbing shell edge K.1, which area lies on the front holding ring edge K.3, [0099] an obliquely rising segment 19.v of the front edge area 19, wherein the segment 19.v lies on the obliquely rising area K.3v of the front holding ring edge K.3, [0100] a centrally arranged, oblong projection 28, and [0101] two serrated edges 20.1, 20.r.

[0102] The helmet shell 2 comprises a centrally arranged groove 29. The oblong projection 28 engages with the groove 29.

[0103] The second embodiment according to FIG. 12 and FIG. 13 additionally comprises [0104] a front, centrally arranged projection 21.v and [0105] a rear, centrally arranged projection 21.h.

[0106] In one embodiment, a distance is formed between the two serrated edges 20.1, 20.r and two corresponding serrated areas 23.1, 23.r of the front holding ring edge K.3 during regular use. The front edge area 19 moves under a higher load in the direction of the front holding ring edge K.3. The two serrated edges 20.1, 20.r lie temporarily on the serrated areas 23.1, 23.r in case of a very high mechanical load only. As a result, forces are diverted. In another embodiment, the two serrated edges 20.1, 20.r lie permanently on the serrated areas 23.1, 23.r.

[0107] FIG. 14 and FIG. 15 show from the inside an embodiment of the helmet shell 2, which matches the second embodiment of the shock-absorbing shell 1 (FIG. 12 and FIG. 13) and may also be used together with the first embodiment (FIG. 10 and FIG. 11). Two projections 22.v, 22.h arranged centrally one behind another can be seen. The centrally arranged projection 21.v at the top on the shock-absorbing shell 1 engages in one embodiment with the space between these two projections 22.v, 22.h on the inside at the stop element for the projection 21.v. In conjunction with the projection 21.v, these stop elements 22.v, 22.h limit a possible movement of the shock-absorbing shell 1 relative to the helmet shell 2 in the viewing direction BR and opposite the viewing direction BR.

[0108] In another embodiment, the projection 21.v of the shock-absorbing shell 1 is in contact with the rear projection 22.h of the helmet shell 2. The projection 22.v belongs to a snap-in connection for the visor 7.

[0109] The rear projection 21.h at the top on the shock-absorbing shell 1 engages with an outwards pointing and centrally arranged groove 29 in the rear area of the helmet shell 2. As a result, the projection 21.h prevents a movement of the shock-absorbing shell 1 relative to the helmet shell 2 at right angles or obliquely to the viewing direction BR.

[0110] In an alternative embodiment, the helmet shell 2 matches the first embodiment of the shock-absorbing shell 1 (FIG. 10 and FIG. 11). The helmet shell 2 according to this alternative embodiment does not preferably have the two projections 22.v, 22.h, which are shown in FIG. 14 and FIG. 15.

[0111] The two serrated areas 20.1, 20.r of the shock-absorbing shell edge K.1 can be moved in the viewing direction BR up to the serrated areas 23.1, 23.r of the front holding ring edge K.3 of the front holding ring part 3. As a result, the serrated areas 23.1, 23.r form two stop elements, which limit a movement of the shock-absorbing shell 1 relative to the helmet shell 2 in the viewing direction BR. The shock-absorbing shell 1 reaches these two stop elements 23.1, 23.r in case of a very high load only.

[0112] Especially the following steps are preferably carried out during the assembly of the safety helmet 100: [0113] The components of the safety helmet 100 are provided. They may be manufactured at different locations. [0114] The shock-absorbing shell 1 is inserted into the helmet shell 2 on the inside. [0115] The rear holding ring part 11 is placed on the shock-absorbing shell 1 and is screwed onto the helmet shell 2 from the inside. [0116] The front holding ring part 3 is likewise placed on the shock-absorbing shell 1 and is screwed to the helmet shell 2 from the inside. [0117] The front bearing ring part 6 is connected to the front holding ring part 3. [0118] The rear bearing ring parts 7.1, 7.r, 10 are likewise connected to the front holding ring part 3. [0119] The front bearing ring part 6 is connected to the rear bearing ring parts 7.1, 7.r.

[0120] The shock-absorbing shell 7 is preferably inserted first into the helmet shell 2 on the inside. The holding ring parts 11, 3 as well as the bearing ring parts 6, 7.1, 7.r, 10 are subsequently connected to the helmet shell 2.

[0121] While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.

LIST OF REFERENCE CHARACTERS

[0122] 1 Arched shock-absorbing shell, inserted into the helmet shell 2 on the inside; it comprises the lateral recesses 17.1, 17.r, the central recess 18, the two central projections 21.h, 21.v as well as the shock-absorbing shell edge K.1

[0123] 2 Arched helmet shell made of a hard material, to which the front holding ring part 3 and the rear holding ring part 11 are attached

[0124] 3 Front holding ring part in the form of a half ellipse, connected from the inside by the screw connections 16.1, 16.r to the helmet shell 2; it has the front holding ring edge K.3

[0125] 4 Pivotable visor, attached to the helmet shell 2

[0126] 5.1 Left screw connection, which connects the additional visor 26 pivotably to the front holding ring part 3

[0127] 5.r Right screw connection, which connects the additional visor 26 pivotably to the front holding ring part 3

[0128] 6 Front bearing ring, attached by means of the intermediate piece 27 to the front holding ring part 3, detachably connected to the left rear bearing ring part 7

[0129] 7 Two-part rear bearing ring part; it comprises the two parts 7.1 and 7.r, detachably connected to the front bearing ring part 6

[0130] 7.1 Left part of the rear bearing ring part 7, connected movably to the central rear bearing ring part 10

[0131] 7.r Right part of the rear bearing ring part 7, connected movably to the central rear bearing ring part 10

[0132] 8.1, 8.r Holding arms at the front holding ring part 3

[0133] 9.1, 9.r Holding arms at the rear bearing ring part 7

[0134] 10 Central rear bearing ring part, configured as a bearing support for the back of the head or as a nape bearing support, connected to the rear bearing ring part 7 and to the rear holding ring parte 11

[0135] 11 Rear holding ring part, arranged behind the rear bearing ring parts 7, 10; it comprises the through holes 12.1, 12.2; it has the rear holding ring edge K.11

[0136] 12.1, 12.r Through holes at the rear holding ring part 11, through which the screws 24.1, 24.r are passed

[0137] 13.1, 13.r Lateral projections, arranged laterally at the top at the rear holding ring part 11; they engage with the projections 17.1, 17.r

[0138] 14 Centrally arranged, resilient projection at the top at the rear holding ring part 11; it engages with the recess 18 in the shock-absorbing shell 1

[0139] 15 Handwheel for adjusting the head size of the safety helmet 100

[0140] 16.1 Left screw connection, which detachably connects the front holding ring part 3 to the helmet shell 2 and detachably and pivotably connects the visor 4 to the helmet shell 2

[0141] 16.r Right screw connection, which detachably connects the front holding ring part 3 to the helmet shell 2 and detachably and pivotably connects the visor 4 to the helmet shell 2

[0142] 17.1, 17.r Lateral recesses in the shock-absorbing shell 1, with which the projections 13.1, 13.r at the holding ring part 11 engage

[0143] 18 Central recess in the edge of the shock-absorbing shell 1, with which the resilient projection 14 engages

[0144] 19 Downwards pointing, front edge area of the shock-absorbing shell edge L.1; it lies on the obliquely rising area K.3v of the front holding ring edge K.3 of the front holding ring part 3; it comprises the segment 19.v

[0145] 19.v Obliquely rising segment of the front edge area 19 of the shock-absorbing shell edge K.1; it lies on the front holding ring edge K.3

[0146] 20.1, 20.r Serrated areas of the shock-absorbing shell edge K.1; they are normally located at a distance from the serrated areas 23.1, 23.r of the front holding ring edge K.3; they lie on these in case of a very high load

[0147] 21.h Rear central projection at the shock-absorbing shell 1; it engages with the groove 29

[0148] 21.v Front central projection at the shock-absorbing shell 1; it abuts against the stop elements 22.h and 22.v

[0149] 22.h Rear, centrally arranged projection in the helmet shell 2; it forms a stop element for the projection 21.v in one embodiment; it belongs to a snap-in connection for the visor 7 in one embodiment

[0150] 22.v Front, centrally arranged projection in the helmet shell 2; it forms a stop element for the projection 21.v

[0151] 23.1, 23.r Serrated areas of the front holding ring edge K.3

[0152] 24.1, 24.r Screws, which are passed through the through holes 12.1, 12.r and are screwed into the threads 25.1, 25.r and thereby hold the rear holding ring part 11 on the inside at the helmet shell 2

[0153] 25.1, 25.r Thread on the inside in the helmet shell 2 for the screws 24.1, 24.r

[0154] 26 Additional visor in the form of sunglasses, arranged between the front holding ring parte 3 and the helmet shell 2, attached to the helmet shell 2 with the screw connections 5.1 and 5.r

[0155] 27 Intermediate piece between the front holding ring part 3 and the front bearing ring part 6 Centrally arranged, oblong projection on the outside at the shock-absorbing shell 1; it engages with the groove 29

[0156] 29 Outwards pointing and centrally arranged groove in the rear area of the helmet shell 2, with which the projection 28 engages

[0157] 100 Safety helmet, comprising the helmet shell 2, the shock-absorbing shell 1, the visor 4, the additional visor 26, the holding ring 3, 11, the bearing ring 6, 7, 10, the intermediate piece 27 and the handwheel 15

[0158] BR Viewing direction of a user of the safety helmet 100, who is looking straight forward

[0159] K.1 Shock-absorbing shell edge, downwards pointing edge of the shock-absorbing shell 1; it comprises the front edge area 19 and the serrated areas 20.1, 20.r

[0160] K.3 Front holding ring edge, upwards pointing edge of the front holding ring part 3; it comprises the front area K.3v

[0161] K.3v Obliquely rising front area of the front holding ring edge K.3

[0162] K.11 Upwards pointing rear holding ring edge of the rear holding ring part 11