In-mold protective helmet having integrated ventilation system

Abstract

The present invention provides a lightweight protective helmet having an improved ventilation system therein. The protective helmet comprises an outer shell and an inner liner that are joined together to form a shell/liner composite. The ventilation system interacts with one or more ventilation ports in the protective helmet to control the flow of ambient air in and out of the interior of the protective helmet. The ventilation system may be integrated or encased within the shell/liner composite, or it may be adapted to be used on the exterior of the helmet. In addition, the ventilation system may include one of several types of interchangeable insert members to allow active or passive control of ambient air into the interior of the helmet.

What is claimed is:  
     
         1 . An in-mold protective helmet comprising: 
 an outer shell;    an inner liner comprised of impact absorbing material having suitable impact attenuation properties to protect a wearer of said protective helmet, said inner liner joined to said outer shell using an in-mold process to form a shell/liner composite;    a plurality of ventilation ports positioned within said protective helmet, said ventilation ports providing an access for ambient air to enter and exit an interior portion of said protective helmet;    a ventilation system integrally formed with said protective helmet and interacting with at least one of said plurality of ventilation ports to control flow of said ambient air into and out of said interior portion of said protective helmet, said ventilation system comprising: 
 an upper portion;  
 a lower portion;  
 a vent space defined by the formation of said upper portion with said lower portion; and  
 a vent shield contained within said vent space, said vent shield capable of displacing within said vent space in relation to said at least one ventilation port.  
   
     
     
         2 . The in-mold protective helmet of  claim 1 , wherein said vent space is contained within said inner liner such that said upper portion and said lower portion of said ventilation system are each comprised of a portion of said inner liner.  
     
     
         3 . The in-mold protective helmet of  claim 1 , wherein said vent space is contained within said inner liner such that said upper portion comprises the interior surface of said outer shell and said lower portion comprises a portion of said inner liner, said vent space being directly adjacent said interior surface of said outer shell.  
     
     
         4 . The in-mold protective helmet of  claim 1 , wherein said vent space is contained within said inner liner such that said upper portion comprises a portion of said interior liner and said lower portion comprises an insert member fittable within said vent space.  
     
     
         5 . The in-mold protective helmet of  claim 4 , wherein said insert piece is formed of material similar to that of said inner liner.  
     
     
         6 . The in-mold protective helmet of  claim 1 , wherein said vent space is entirely contained within one of said outer shell and said inner liner, such that a portion of said outer shell and said inner liner serves as both said upper and lower boundaries of said vent space.  
     
     
         7 . The in-mold protective helmet of  claim 1 , wherein said vent space comprises an independently created vent box removably attachable to said protective helmet  
     
     
         8 . The in-mold protective helmet of  claim 1 , wherein said vent space is defined by a vent box utilizing said outer shell as one of an upper and lower boundary.  
     
     
         9 . The in-mold protective helmet of  claim 1 , wherein said vent space is defined by a vent box utilizing said inner liner as one of an upper and lower boundary.  
     
     
         10 . The in-mold protective helmet of  claim 1 , wherein said vent space is a removable insert member that fits within and functions with a portion of said protective helmet to define said vent space.  
     
     
         11 . The in-mold protective helmet of  claim 1 , wherein said vent space is defined by said outer shell serving as one boundary and a second shell or attachable piece serving as another boundary.  
     
     
         12 . The in-mold protective helmet of  claim 1 , wherein said vent space is defined by a recess in said outer shell and said inner liner serving as said lower member and a removable insert piece fittable within said recess serving as said upper portion.  
     
     
         13 . The in-mold protective helmet of  claim 1 , wherein said vent space is defined by an independent upper member coupled to an independent lower member to create said vent space, said independent upper and lower members forming an independent insert member attachable to said in-mold protective helmet over one or more of said ventilation ports.  
     
     
         14 . The in-mold protective helmet of  claim 1 , further comprising an actuator coupled to said vent shield and extending to the exterior of said protective helmet to actuate said displacement of said vent shield.  
     
     
         15 . The in-mold protective helmet of  claim 1 , wherein said in-mold process comprises molding said inner liner to said outer liner.  
     
     
         16 . The in-mold protective helmet of  claim 1 , wherein said in-mold process comprises bonding said inner liner to said outer liner.  
     
     
         17 . An in-mold protective helmet comprising: 
 an outer shell;    an inner liner comprised of impact absorbing material having suitable impact attenuation properties to protect a wearer of said protective helmet, said inner liner joined to said outer shell using an in-mold process to form a shell/liner composite;    a plurality of ventilation ports positioned within said protective helmet, said ventilation ports providing an access for ambient air to enter an interior portion of said protective helmet;    a ventilation system operable with at least a portion of said shell/liner composite and interacting with at least one of said plurality of ventilation ports to control said access of said ambient air to said interior portion of said protective helmet, said ventilation system comprising: 
 an interchangeable insert member having a vent space therein.  
   
     
     
         18 . The protective helmet of  claim 17 , wherein said interchangeable insert member is an active, self-contained ventilation system comprising: 
 a vent box formed by coupling an upper member to a lower member to define said vent space;    a vent shield contained within said vent space of said vent box, said vent shield capable of displacing within said vent box in relation to said at least one ventilation port; and    an actuator coupled to said vent shield for activating said displacement of said vent shield.    
     
     
         19 . An in-mold protective helmet comprising: 
 an outer shell;    an inner liner comprised of impact absorbing material having suitable impact attenuation properties to protect a wearer of said protective helmet, said inner liner joined to said outer shell to form a shell/liner composite, said shell/liner composite having at least one recessed portion therein, said recessed portion containing a ventilation port through which ambient air may flow into an interior portion of said protective helmet;    a ventilation system operable with said ventilation port within said recessed portion to control said ambient air flow, said ventilation system comprising: 
 a vent space formed by an upper and lower member; and  
 a vent shield contained within said vent space, said vent shield capable of displacing within said vent box relative to said ventilation port.  
   
     
     
         20 . The in-mold protective helmet of  claim 19 , wherein said lower member is comprised of a portion of said outer shell located within said recessed portion.  
     
     
         21 . The in-mold protective helmet of  claim 19 , wherein said lower member is comprised of a portion of said inner liner located in said recess.  
     
     
         22 . The in-mold protective helmet of  claim 19 , wherein said upper member is comprised of an insert member capable of removably fitting and being coupled within said recessed portion.  
     
     
         23 . The in-mold protective helmet of  claim 19 , wherein said upper member is comprised of a second shell.