HELMET AND FABRICATION METHOD

Description

BACKGROUND OF THE INVENTION

The invention relates to a helmet and to its manufacturing method.

PRIOR ART

In the fields of rope access work, rope access technicians are equipped with a great deal of safety equipment including a helmet. The helmet is designed to be fixed on the head and has to protect the user against the different types of impacts. To withstand increasingly violent impacts without increasing the weight of the helmets, work has been carried out on the crown as regards both the shape and the materials constituting the latter, and also as regards the means for attaching the crown to the user's head.

In addition to these issues, a requirement also exists as regards control of the temperature inside the helmet, more particularly when the outside temperature rises and/or intense efforts are made.

To improve thermal comfort, the helmet can be provided with one or more through holes that open out facing the user's head so as to create an air flow. This air flow enables the space between the head and the crown or the foam liner to be swept to reduce the temperature inside the helmet.

For obvious safety reasons, while at the same time keeping a reasonable size and weight, it is not possible to make holes in a large number of parts of the crown, with the result that the holes are generally present on the right and left lateral portions of the crown.

Independently from its position on the crown, the presence of a through hole passing through the thickness of the crown corresponds to the presence of a tunnel that opens out directly facing the user's head. It is apparent that under some particular conditions, in particular in tree-pruning activities, a branch or other slender item may pass through the tunnel and strike the user's head when a relative movement occurs between the branch and crown, for example a branch that moves with a substantially horizontal movement directed towards the inside of the volume delineated by the crown.

To avoid such a nuisance, certain pruning helmets are not provided with through holes, thereby preventing formation of an air flow in the upper part of the inside volume of the helmet. An alternative embodiment consists in making holes of small cross-section. As the cross-section is small, the air flow is very limited, which means that a large number of holes are required. Nevertheless, formation of a large number of holes naturally results in an impairment of the mechanical performances, requiring other modifications to be made on the crown.

It is observed that it is difficult to form a helmet for mountaineering or for working at heights that enables a significant air flow to be had in the top part of the crown while at the same time providing a high degree of protection.

It is observed that the problem of ventilation is also present in other categories of helmets, in particular skiing helmets that have a rigid crown inside which a foam liner is placed. The crown defines through holes, and the foam liner also defines through holes that are staggered and/or a netting is fitted between the crown and foam liner. It should be noted that the ventilation problems are different as the skier is moving at high speed, the activity takes place in rather low temperatures and the impacts present a different typology, thus enabling other trade-offs to be made as regards the configuration and position of the through holes, with the result that the holes are mainly provided on the top of the helmet. Furthermore, such a configuration is not attractive for a helmet for mountaineering or for working at heights, as it implies providing a helmet that is heavier and more voluminous in order to comply with different regulatory requirements, in particular as regards the resistance to perforating impacts arising from objects falling on the top of the helmet.

OBJECT OF THE INVENTION

One object of the invention consists in providing a helmet that enables a better trade-off to be made between protection and ventilation of the inside of the crown without impairing the other parameters of the helmet.

This issue tends to be solved by means of a helmet designed for working at heights and for mountaineering comprising:

• • a crown having a peak and a base provided with a crown wall delineating several first through holes separated by first studs to form a first ventilation area, the crown extending in a heightwise direction between the base and the peak;
  • a cap delineating a space receiving a user's head.

The helmet is remarkable in that it comprises a diverter attached to the crown and arranged between the crown and the space designed to receive a user's head delineated by the cap to divert an object entering via one of the first through holes;

• • in that the diverter has a diverting wall facing the first ventilation area in a first direction perpendicular to the heightwise direction, the diverting wall extending in the direction of the peak up to a top end;
  • in that the inner wall of the crown and the diverter form a duct opening out in the direction of the peak of the crown and flaring in the direction of the peak of the crown; and
  • in that the top end is located between the cap and the inner wall of the crown so that any imaginary line tangent to the top end and passing through the first through holes passes through the crown without passing through the space receiving the user's head delineated by the cap.

In a preferred embodiment, the diverter delineates several second through holes separated by second studs to define a second ventilation area. The second through holes have a smaller area than an area of the first through holes facing the second through holes in the first direction.

Preferentially, each first through hole is facing at least two second through holes in the first direction.

In advantageous manner, the diverter is installed removable from the crown.

Preferentially, a shutter is installed movable with respect to the first ventilation area between a closed position where the first through holes are blocked by the shutter and an open position where the shutter is not facing the first through holes in the first direction.

According to one embodiment, the diverter is installed movable with respect to the crown between a protection position and another position in which the shutter is installed fixedly secured to the diverter. The protection position is a position where the diverting wall is facing the first ventilation area in the first direction. The other position corresponds to the closed position of the shutter.

It is a further object of the invention to provide a manufacturing method of a helmet that enables a trade-off between ventilation and protection of the head to be improved.

This result tends to be achieved by means of a method for manufacturing a helmet comprising the following steps:

• • providing a helmet and a diverter, the helmet comprising a crown and a cap, the crown having a peak and a base defining a supporting plane, the crown being provided with a crown wall delineating several first through holes separated by first studs to form a first ventilation area, the cap delineating a space designed to receive a user's head;
  • attaching the diverter to the crown, the diverter being arranged between the crown and the cap to divert an object entering via one of the first through holes;
    wherein the diverter is facing the first ventilation area in a first direction parallel to the supporting plane;
    wherein in a cutting plane perpendicular to the supporting plane and in an observation in a heightwise direction perpendicular to the supporting plane and directed from the supporting plane to the peak, the inclined surface of the diverter moves away from the surface of the crown mainly in the direction of the peak of the crown without passing through the space designed to receive the user's head delineated by the cap.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages and features will become more clearly apparent from the following description of particular embodiments and implementation modes of the invention given for non-restrictive example purposes only and represented in the appended drawings, in which:

FIG. 1 schematically illustrates a perspective view of a helmet provided with a diverter in the protection position and defining second through holes;

FIG. 2 schematically illustrates a side view of a helmet provided with a diverter in the protection position and defining second through holes;

FIG. 3 schematically illustrates a perspective view of the inside of a helmet provided with a diverter in the protection position and defining second through holes;

FIG. 4 schematically illustrates a perspective view of the inside of a helmet provided with a diverter in the closed position and defining second through holes;

FIG. 5 schematically illustrates a perspective view of a crown of a helmet provided with a diverter in the closed position and extended by a shutter closing the first through holes;

FIG. 6 schematically illustrates a side view of a crown of a helmet provided with a diverter in the closed position and extended by a shutter closing the first through holes;

FIG. 7 schematically illustrates a perspective view of a cross-section along a median sagittal plane of a crown of a helmet provided with two attachment devices designed to pass through the crown to form fixing brackets of the diverter;

FIG. 8 schematically illustrates a perspective view of a cross-section along a median sagittal plane of the crown provided with two fixing brackets and with the diverter in the course of installation;

FIG. 9 schematically illustrates a side view of a cross-section along a median sagittal plane of the crown provided with two fixing brackets and with the diverter attached to the crown;

FIG. 10 schematically illustrates an enlarged view of a detail of the diverter fixed to the fixing bracket and of the shutter along the cutting plane AA illustrated in FIG. 9 and with a view of the air flows that enter and pass through the crown, the diverter being in the protection position;

FIG. 11 schematically illustrates an enlarged view of a detail of the diverter fixed to the fixing bracket and of the shutter along the cutting plane AA illustrated in FIG. 9, the diverter being in the closed position;

FIG. 12 schematically illustrates a view of a diverter defining second through holes and forming a shutter;

FIG. 13 schematically illustrates a view of a diverter not provided with the second through holes and forming a shutter;

FIG. 14 schematically illustrates a view of an installation of a cap in a crown.

DESCRIPTION OF THE EMBODIMENTS

FIGS. 1 to 11 represent a protection helmet 1 provided with a crown 2 and a cap 3. The cap 3 is designed to receive the user's head. The cap 3 enables the user's head to be placed at a distance from the crown 2. The cap 3 is preferentially fixed to the crown 2. The cap 3 can be in the form of a set of wire elements, for example webbing straps, as is well known in the technical field to define an empty space propitious to creating an air flow.

The crown 2 is made from a material that is unable to fold onto itself. The crown 2 can preferentially be made from a plastic material for example from polycarbonate or injection-moulded ABS or from polystyrene or expanded polypropylene, or from any other plastic material, in particular injection-moulded, thermoformed or foam plastic.

The crown 2 has a peak 2a and a base 2b. The crown wall extends from the base 2b to the peak 2a in a heightwise direction ZZ that corresponds substantially to the longitudinal direction of the user once the helmet is being worn.

The base 2b can define a supporting plane that corresponds to the horizontal plane tangent to the lowest point of the crown 2 when the user is wearing the helmet 1. Preferentially, the supporting plane is defined by at least three points of the base 2b that are pressing on a plane when the helmet 1 is placed on a support. FIG. 2 illustrates the supporting plane AA.

The crown 2 defines a crown surface that represents the surface of the median plane of the crown in the thickness direction. The crown surface is a curved surface that is approximately a half-sphere.

To remove of a part of the heat given off by the user's head, the crown 2 has a crown wall that defines several first through holes 4. The first through holes 4 are preferentially right first holes and left first holes, i.e. first holes arranged in the right-hand part and the left-hand part with respect to a median sagittal plane of a user wearing the helmet 1. It is also advantageous for the right first through holes and the left first through holes to be arranged symmetrically with respect to the median sagittal plane. It is further possible to have front first holes and/or back first holes as alternatives or as complements to the right and left first holes.

As illustrated in FIGS. 1, 2, 3 and 4 and in FIGS. 7 to 10, the first through hole 4 is pass-through in the thickness direction, i.e. in the direction connecting the inner face of the crown 2 and the outer face of the crown 2. The first through holes 4 are also pass-through in a first direction that is parallel to the supporting plane AA.

The right and left first through holes 4 are designed to enhance the presence of an air flow inside the helmet 1 between the crown 2 and the user's head, at least in the top part of the crown 2. The first through holes 4 can be of any shape. The shape of the first through holes 4 can differ between the multiple first through holes 4.

The first through holes 4 are separated from one another by first studs 5. The first through holes 4 define a first area. It was observed that to have an air flow ensuring an efficient heat removal, it is necessary to have large first through holes 4. The first through holes 4 have large cross-sections without penalising the mechanical performances of the crown 2 in response to impacts.

To encourage the presence of an efficient air flow, the first through holes 4 each have a first area that is as large as possible, for example more than 1 cm², preferentially more than 2 cm², more preferentially more than 5 cm² and even more preferentially more than 8 cm² or 10 cm².

However, the larger the value of the first area, the easier it is for the cross-section of a foreign body, for example a twig or branch, to get inside the crown 2. Furthermore, the risk of injury increases with the cross-section of the foreign body.

To maintain a large air flow while reducing the probability of the head coming into contact with a foreign body entering from outside the crown 2, the helmet 1 is provided with a diverter 6. The diverter 6 comprises a diverting wall 6′ arranged inside the volume bounded by the crown 2 and the volume designed to receive the head and represented by the cap 3. The diverter 6 is located facing the first through holes 4 in the first direction. The diverter 6 is located between the crown 2 and the cap 3, i.e. between the crown 2 and the volume representative of the user's head.

Preferentially, the diverter 6 is fixed to the crown 2. The diverter 6 has a diverting wall 6′ that is distinct from the crown wall. The diverting wall 6′ is rigid or substantially rigid.

The diverting wall 6′ is for example made from plastic, metal or wood. The diverting wall 6′ is not a netting attached to the crown 2.

In a particular embodiment, the diverting wall 6′ opposes a thrust force with a value of 1 kN in the direction of the cap 3. This prevents a foreign body from reaching the user's head.

The diverting wall 6′ extends from the area facing the first through holes 4 in the direction of the peak 2a of the crown 2. The diverting wall 6′ is terminated by a top end that represents the end closer to the peak 2a, i.e. opposite a bottom end that is closer to the base 2b. Such resistance is not possible with the cap 3, which must be flexible to provide the expected comfort.

The diverting wall 6′ defines at least one portion with an inclined surface that is globally directed towards the peak 2a of the crown 2. The inclination of the diverting wall 6′ enables a foreign body that enters from outside through one of the first through holes 4 to slide against the diverting wall 6′ and be directed towards the peak 2a of the crown 2. More precisely, the diverting wall 6′ is inclined in the direction of the space situated between the peak of the cap 3 and the peak 2a of the crown 2 without passing through the surface delineated by the cap 3.

The top end of diverting wall 6′ is located between the crown 2 and the cap 3 so that any imaginary line tangent to the top end and passing through the first through holes 4 passes through the crown 2 without passing through the space receiving the user's head delineated by the cap 3. A foreign body can enter the crown through a first through hole 4. The foreign body comes into contact with the diverting wall 6′ and slides along the diverting wall 6′ until it leaves the diverter 6. The foreign body is then tangent to the top end. The alignment between the top end and the first through holes prevents a rectilinear foreign body from being able to penetrate into the volume designed to receive the user's head.

The diverting wall 6′ will oppose movement of the foreign body in the first direction in the direction of the cap 3 to prevent contact with the user's head and/or the inclination will direct the foreign body to the space situated between the peak of the cap 3 and the peak 2a of the crown 2 without passing through the cap 3, so that the foreign body moves in an area where the risk of contact with the head is very slight or even nil. This avoids having to form a diverter 6 that is stronger and therefore bulkier and heavier. The deviation can result in the foreign body being wedged against the first studs 5, thereby also reducing the risk of injury. If the foreign body enters the helmet 1 with a downward path, the diverter 6 moves towards the crown 2 and forms a blocking part. The deviation wall 6′ prevents the external element from penetrating into the crown 2 until it reaches the space intended to receive the user's head or press on the cap 3.

For example, the diverter 6 defines an inclined surface that extends mainly in a direction connecting the peak 2a of the crown 2 and the right or left lower end of the crown 2 depending on whether the diverter 6 is fixed to the right part or to the left part of the crown 2. The angle of inclination of the diverting wall 6′ and especially the position of the top end can be adjusted according to the position of the first through holes 4, the curvature of the crown 2 and the available space between the cap 3 and the crown 2. The same can be the case for an installation on the rear or front part of the crown 2.

The diverter 6 has an inclination close to that of the crown 2 in the area facing the first ventilation area while being different in order not to reduce the volume accessible for the user's head without reducing the ability to accept an air flow.

In an observation along a cutting plane perpendicular to the supporting plane AA, the wall of the crown 2 and the wall of the diverter 6 are distant and move away from one another when moving in a heightwise direction ZZ perpendicular to the supporting plane away the supporting plane AA in the direction of the peak 2a. In other words, the structure delineated on the one hand by the wall of the crown 2 and on the other hand by the wall of the diverter 6 flares out in the direction of the peak 2a. The diverting wall 6′ and the inner wall of the crown define a duct that opens out to enable an air flow to pass in a top part of the helmet 1. The duct flares out in the direction of the peak 2a to facilitate the presence of a large air flow.

It is particularly advantageous for the diverter 6 not to define a surface parallel to the surface of the crown 2 and for the diverter 6 to move progressively away from the crown 2 when moving away from the supporting plane AA. Observation of the separating distance between the crown 2 and the diverter 6 is made in sectional planes that are perpendicular to the supporting plane AA. The separation between the crown 2 and the diverter 6 enhances the formation of an air flow in the inner top part of the crown 2 eliminating formation of an obstacle above the area receiving the user's head. It is also advantageous to form a rim in order to have a minimum separating distance between the crown wall that defines the first through holes 4 and the wall of the diverter 6. This minimum space ensures that a minimum air flow is captured for the helmet 1 to be correctly ventilated.

As illustrated in FIGS. 3, 4, 9 and 10, it is particularly advantageous for the diverter 6 to extend facing the first through holes 4 at least over the whole of the facing surface between the first through holes 4 and the space accessible for the head bounded by the cap 3 in the first direction.

In a preferred embodiment, the diverter 6 extends underneath the first through holes 4. More preferentially, the diverter 6 is in contact with the crown 2 or is separated from the crown 2 by a smaller distance than a threshold value, for example less than 6 mm or less than 4 mm or less than 2 mm, to prevent a foreign body having a larger diameter than the threshold value from passing between the crown 2 and the diverter 6 in the first direction as illustrated in FIGS. 3, 9 and 10 that is parallel to the median sagittal plane and represents the vertical direction. Bringing the crown 2 into contact with the diverter 6 improves the mechanical performances.

As an exemplary embodiment illustrated in FIGS. 1 to 4, the crown 2 defines a rim defining the first through holes 4. The attachment between the diverter 6 and the crown 2 is situated on one side of the rim whereas the first through holes 4 are situated on the other side of the rim.

To enhance the air intake, it is advantageous for the wall of the diverter 6 to be offset from the wall of the crown 2 by several millimetres. It is particularly advantageous for the diverter 6 not to be in contact with the crown 2 and for the wall of the diverter 6 to extend in the direction of the top part of the crown 2 so as to form an opening enhancing removal of the air flow in the top part of the crown 2. The air passing through the crown 2 comes into contact with the diverter 6 that does not delineate a closed volume. As the diverter 6 moves progressively away from the crown 2 when approaching the peak 2a, it is easy for the air that enters to flow towards the peak 2a of the crown 2 thereby achieving an air flow that is able to remove heat.

As illustrated in FIGS. 1 to 4, to facilitate the presence of an air flow as close as possible to the top of the user's head, it is advantageous for the diverter 6 to define several second through holes 7 arranged facing the first ventilation area. The facing direction is the first direction.

The second through holes 7 are separated from one another by second studs 8.

It is advantageous for the second through holes 7 to be facing the first through holes 4 and more preferentially for the second through holes 7 to present a smaller cross-section than the cross-section of the first through holes 4. A large quantity of air enters via the first through holes 4 and a part of this quantity of air passes through the second through holes 7, the rest passing along the second studs 8 in the direction of the peak 2a of the crown 2.

As the diverter 6 is located inside the crown 2, it is not intended to withstand the same impacts as the crown 2. It is advantageous to form a diverter 6 that is as ventilated as possible in order not to limit the air flow entering via the first through holes 4 too greatly.

To encourage the presence of an air flow without penalising protection, it is advantageous for the second through holes 7 to have a size that is smaller than a threshold value. It is also advantageous for one or more second through holes 7 to be directly facing a first through hole 4 and more advantageously for each first through hole 4 to be directly facing several second through holes 7.

Preferentially, when the diverter 6 is provided with the second through holes 7, it is advantageous for the diverter 6 to be provided with a ledge 6a installed under the second through holes 7 and extending facing at least 50% of the overlap area between the first through holes 4 and the second through holes 7 in the heightwise direction ZZ, more preferentially over at least 75% of the overlap surface and even more preferentially over at least 100% of the overlap surface. Such an embodiment is illustrated in FIGS. 4 and 5.

FIG. 12 illustrates an embodiment of a diverter 6 defining second through holes 7 and FIG. 13 illustrates an embodiment of a diverter 6 devoid of second through holes 7.

It is particularly advantageous for the diverter 6 to be fixed to the crown 2 and more preferentially to be fixed to the crown 2 by attachment points situated between and/or under the first through holes 4 so as to provide a strong fixing able to withstand a mechanical stress by a foreign body without penalising the air flow.

In a particular embodiment, the diverter 6 is installed movable with respect to the crown 2 between a protection position and another position. In the protection position, the inclined wall of the diverter 6 is arranged facing the first through holes 4. In the other position, the inclined wall is not facing the first through holes 4. The other position can be a complete shuttering position of the first through holes 4 to prevent supply of an air flow to the inside of the crown 2 or an integral access position, i.e. a position enabling the cap 3 to be accessed from the outside of the crown 2 by passing through the first through holes 4 for elements of large size.

It is particularly advantageous for the diverter 6 to be installed movable in translation or in rotation with respect to the crown 2 to define the first position and the other position.

In the embodiment illustrated in FIGS. 3, 4, 7 and 9, the crown 2 defines several rails 9 that extend mainly in a direction connecting the peak 2a of the crown 2 and the bottom end of the crown 2. The diverter 6 defines grooves 10 having complementary shapes to those of the rails 9. This configuration with the grooves 10 and the rails 9 enables movement of the diverter 6 to be reduced or prevented with respect to the crown 2 in the direction perpendicular to the direction of extension of the rails 9. When the diverter 6 is provided removable from the crown 2, this configuration enables the position of the diverter 6 with respect to the crown 2 to be imposed.

The rails 9 and the grooves define a slideway between the crown 2 and the diverter 6 so that the diverter 6 moves in translation with respect to the crown 2. In more general manner, the crown 2 can form one or more grooves 10 and the diverter 6 can form one or more rails 9. Advantageously, the diverter 6 is attached to the crown 2 by several fixing brackets 11 that can be in the form of clips. It is preferable to provide for the clips to be removable from the crown 2 and for the fixing brackets 11 to operate in conjunction with the diverter 6 to secure the fixing brackets 11 and the diverter 6 fixedly to the crown 2.

It is advantageous for the crown 2 to define a hole 12 for each fixing bracket 11 to pass and for the fixing bracket 11 to pass through the crown 2 and the diverter 6 to attach the diverter 6 fixedly with the crown 2. In the absence of the diverter 6, the fixing bracket 11 is not able to be fixed to the crown 2, which prevents a salient part from being formed inside the crown 2.

Except for the second through hole(s) 7, the diverter 6 does not form a closed volume with the crown 2 in order not to penalise the air flow too much. It is advantageous for the diverter 6 to delineate, with the crown 2, an opening extending over the whole length of the first ventilation area, i.e. extending along the direction connecting all the first through holes 4 on one side of the crown 2.

Preferentially, the second through hole 7 has a second area smaller than the first area defined by the first through hole 4 facing the latter in the first direction. The diverter 6 defines second studs 8 having a smaller length than the length of the first through hole 4 facing the latter in the first direction.

As the diverter 6 is installed at a distance from the first through hole or holes, it is possible to install a shutter 13 configured to adjust the effective cross-section of the first through hole or holes 4 by partially or totally blanking off the first through hole or holes 4. Operation of the shutter 13 can be independent from the diverter 6 and even be independent from the presence or absence of a diverter 6. The shutter 13 can be fixed to the crown 2 and configured to slide with respect to the crown 2 to partially or totally block off one or more first through hole(s) 4, to reduce or increase the effective area allowing an air flow to pass. FIGS. 1 and 2 illustrate a shutter 13 in a position that allows a maximum air flow. FIGS. 5 and 6 illustrate a shutter 13 in the closed position to block the air inlet.

In the illustrated embodiment, the shutter 13 is installed fixedly with respect to the diverter 6 and the diverter 6 is installed movable with respect to the crown 2. The diverter 6 defines a protection position allowing an air flow with the diverter 6 located between the first through holes 4 and the cap 3 in the first direction and a closed position where the shutter 13 blocks the first through holes 4. FIG. 10 illustrates the diverter 6 in the protection position and FIG. 11 illustrates the diverter 6 in the closed position.

The crown 2 comprises a front part situated at the front, i.e. close to the user's forehead and an occipital part situated at the rear. The front part is separated from the occipital part by two respectively right and left lateral parts. The protection helmet 1 is preferentially provided with a headband with a front portion and a rear portion. The rear portion can be a neckband. The headband is fixed to the crown 2 so as to form a ring designed to pass round the user's head.

FIG. 10 illustrates two air flows that enter the volume delineated by the crown 2 through a first through hole 4. A part of the air flow passes through a second through hole 7 to reach a user's head. The other part of the air flow slides along the diverter 6 and is directed towards the top part of the crown 2.

FIGS. 3 and 4 partly illustrate the adjustment device configured to adjust a circumference of a headband with preferably an adjustment knob of headband 16a and movable elements 16b that enable the circumference of the headband to be defined.

In the embodiment illustrated in FIGS. 3 and 4, the crown 2 defines cavities 14 receiving clips 15 fixed to the ends of the cap 3. FIG. 14 illustrates an installation mode of the cap 3 in the crown 2 using the clips 15 and the cavities 14.