Protective helmet and relative method for its production

Abstract

Protective helmet ( 1 ) of the type comprising an outer rigid cap ( 2 ) to which a shock-absorbing shell ( 3 ) made of expanded material is internally fixed and an internal lining ( 5 ) for the comfort of the user. The helmet ( 1 ) comprises at least one intermediate cap ( 4 ) made of non-expanded material situated between the inside of the shock-absorbing shell and the internal comfort lining.

1 . A protective helmet ( 1 ) of the type comprising an outer rigid cap ( 2 ) to which a shock-absorbing shell ( 3 ) made of expanded material is internally fixed, an internal lining ( 5 ) for the comfort of the user, and comprises at least one intermediate cap ( 4 ) made of non-expanded material situated between the inside of said shock-absorbing shell ( 3 ) and said internal comfort lining ( 5 ) wherein said at least one intermediate cap ( 4 ) comprises hooking means ( 6 ) for fixing said internal lining ( 5 ).  
   
   
       2 . The protective helmet according to  claim 1 , wherein said hooking means ( 6 ) are of the temporary type, for removably fixing said internal lining ( 5 ).  
   
   
       3 . The protective helmet according to  claim 2 , wherein said hooking means ( 6 ) are selected from hooking slits, Velcro® strips, pressure buttons, laces and rings, hooks.  
   
   
       4 . The protective helmet according to  claim 1 , wherein said at least one intermediate cap ( 4 ) is made so as to include a thermo-formable material.  
   
   
       5 . The protective helmet according to  claim 4 , wherein said intermediate cap ( 4 ) is made of a material selected from PET (polyethylene terephthalate), PETG (polyethylene terephthalate glycol), polystyrene or PC (polycarbonate).  
   
   
       6 . The protective helmet according to  claim 1 , wherein said intermediate cap ( 4 ) is made of fabric.  
   
   
       7 . The protective helmet according to  claim 1 , wherein said intermediate cap ( 4 ) is made of acoustical material.  
   
   
       8 . The protective helmet according to  claim 1 , wherein said at least one intermediate cap ( 4 ) is made of a high kinetic energy absorbing material.  
   
   
       9 . The protective helmet according to  claim 1 , wherein said intermediate cap ( 4 ) is shaped so as to have aeration channels and/or connection holes between said internal lining ( 5 ) and said shock-absorbing shell ( 3 ).  
   
   
       10 . The protective helmet according to  claim 1 , wherein the internal surface of said intermediate cap ( 4 ) is a support for a decoration.  
   
   
       11 . The protective helmet according to  claim 1 , wherein said intermediate cap ( 4 ) protrudes outside said external cap ( 2 ), to form appendages of said protective helmet ( 1 ).  
   
   
       12 . The cap according to  claim 1 , wherein said shock-absorbing shell ( 3 ) is made of expanded polystyrene and characterized in that said shell is co-molded onto said intermediate cap ( 4 ).  
   
   
       13 . The cap according to  claim 1 , wherein said intermediate cap ( 4 ) is in the form of a film.  
   
   
       14 . A method for fixing an internal lining ( 5 ) for the comfort of the wearer inside a shock-absorbing shell ( 3 ) made of expanded material of a protection helmet ( 1 ), the method comprising the following phases: 
 a. producing an intermediate cap ( 4 ) made of a non-expanded material;    b. fixing said intermediate cap ( 4 ) to the internal surface of said shock-absorbing shell ( 3 );    c. attaching said internal comfort lining ( 5 ) by hooking means ( 6 ) to the internal surface of the intermediate cap ( 4 ).    
   
   
       15 . The method according to  claim 14 , comprising the phase of providing said internal surface of the intermediate cap ( 4 ) with temporary hooking means ( 6 ) for said internal comfort lining ( 5 ), before said phase for attaching the internal lining.  
   
   
       16 . The method according to  claim 15 , wherein said intermediate cap ( 4 ) is made of a thermo-formable material, comprising a shaping phase with channels and/or holes, and/or decorating said intermediate cap before said fixing phase of said intermediate cap to the shock-absorbing shell.  
   
   
       17 . The method according to  claim 15 , wherein said fixing phase of the intermediate cap to the shock-absorbing shell comprises a co-molding phase of said expanded material onto said intermediate cap.  
   
   
       18 . The method according to  claim 17 , wherein said fixing phase of the intermediate cap to the shock-absorbing shell comprises a co-molding phase of said expanded material onto said intermediate cap.