Interlocking co-molded helmet energy management liner

Abstract

A helmet includes a helmet body with an outer shell and an in-molded energy management liner inside the outer shell. The in-molded energy management liner may include an inner liner of a first material and an outer liner of a second material different from the first material, with at least one hole through the inner liner, an inside surface, an outside surface, and sides connecting the inside surface with the outside surface. The outer liner formed around the inner liner such that the outer liner extends through the at least one hole and around at least two of the sides of the inner liner, covering a majority of the outside surface and at least a portion of the inside surface, and both the inner liner and the outer liner are exposed on an inside of the in-molded energy management liner.

1 . A helmet comprising:
 a helmet body having an outer shell and an in-molded energy management liner inside the outer shell, wherein the in-molded energy management liner includes:
 an inner liner of expanded polypropylene (EPP) having at least one hole through the inner liner, an inside surface, an outside surface, and sides connecting the inside surface with the outside surface; and 
 an outer liner of expanded polystyrene (EPS) formed around the inner liner such that the outer liner extends through the at least one hole and around at least two of the sides of the inner liner, covering a majority of the outside surface and at least a portion of the inside surface; and 
   a fit system disposed within the in-molded energy management liner and coupled to the helmet body.   
     
     
         2 . The helmet of  claim 1 , wherein the inner liner comprises one or more standoffs extending outward through the outside surface of the outer liner. 
     
     
         3 . The helmet of  claim 1 , wherein both the inner liner and the outer liner are exposed on an inside of the in-molded energy management liner. 
     
     
         4 . The helmet of  claim 1 , wherein the outer liner engages the inner liner mechanically and without a chemical bond. 
     
     
         5 . The helmet of  claim 1 , wherein the outer liner extends at least partially around all of the sides of the inner liner. 
     
     
         6 . An in-molded energy management liner comprising:
 an inner liner of expanded polypropylene (EPP) having at least one hole through the inner liner, an inside surface, an outside surface, and sides connecting the inside surface with the outside surface; and   an outer liner of expanded polystyrene (EPS) formed around the inner liner such that the outer liner extends through the at least one hole and around at least two of the sides of the inner liner, covering a majority of the outside surface and at least a portion of the inside surface.   
     
     
         7 . The in-molded energy management liner of  claim 6 , wherein the inner liner comprises one or more standoffs extending outward through the outside surface of the outer liner. 
     
     
         8 . The in-molded energy management liner of  claim 6 , wherein both the inner liner and the outer liner are exposed on an inside of the in-molded energy management liner. 
     
     
         9 . The in-molded energy management liner of  claim 6 , wherein the outer liner engages the inner liner mechanically and without a chemical bond. 
     
     
         10 . The in-molded energy management liner of  claim 6 , wherein the outer liner extends at least partially around all of the sides of the inner liner. 
     
     
         11 . A method of assembling a multi-liner helmet, comprising:
 injecting a first material into an inner-liner mold to form an inner liner;   placing the inner liner in an outer-liner mold; and   injecting a second material different from the first material into the outer-liner mold to form an outer liner around the inner liner;   wherein the outer liner extends through at least one hole in the inner liner and around at least two of sides of the inner liner, covering a majority of an outside surface of the inner liner, and both the outer liner and the inner liner are exposed on an inside of an in-molded energy management liner comprising the inner liner and the outer liner.   
     
     
         12 . The method of  claim 11 , wherein the first material is expanded polypropylene (EPP) and the second material is expanded polystyrene (EPS). 
     
     
         13 . The method of  claim 11 , wherein the inner liner comprises standoffs extending outward and injecting a second material comprises injecting the second material such that the standoffs extend outward through an outside surface of the outer liner. 
     
     
         14 . A helmet comprising:
 a helmet body having an outer shell and an in-molded energy management liner inside the outer shell, wherein the in-molded energy management liner includes:
 an inner liner of a first material having at least one hole through the inner liner, an inside surface, an outside surface, and sides connecting the inside surface with the outside surface, and 
 an outer liner of a second material different from the first material formed around the inner liner such that the outer liner extends through the at least one hole and around at least two of the sides of the inner liner, covering a majority of the outside surface and at least a portion of the inside surface, and both the inner liner and the outer liner are exposed on an inside of the in-molded energy management liner. 
   
     
     
         15 . The helmet of  claim 14 , further comprising a fit system disposed within the in-molded energy management liner and coupled to the helmet body. 
     
     
         16 . The helmet of  claim 14 , wherein the first material is EPP and the second material is EPS. 
     
     
         17 . The helmet of  claim 14 , wherein the inner liner comprises one or more standoffs extending outward through the outside surface of the outer liner. 
     
     
         18 . The helmet of  claim 14 , wherein the outer liner engages the inner liner mechanically and without a chemical bond. 
     
     
         19 . The helmet of  claim 14 , wherein the outer liner extends at least partially around all of the sides of the inner liner.