Impact absorbing component for a helmet

Abstract

An impact absorbing component for a helmet is shaped to provide protection for at least a portion of a human skull. The impact absorbing component includes a shaping layer of polymer-based material, and a plurality of impact absorbing parts. The impact absorbing parts are attached to respective portions of a surface of the shaping layer such that the plurality of impact absorbing parts are held by the shaping layer in a predetermined relative arrangement. A method for manufacturing the impact absorbing component, as well as a helmet and method for manufacturing the helmet with the impact absorbing component, are also provided.

What is claimed is: 
     
         1 . An impact absorbing component for a helmet, the impact absorbing component being shaped to provide protection for at least a portion of a human skull, wherein the impact absorbing component comprises:
 a shaping layer of polymer-based material; and   a plurality of impact absorbing parts attached to respective portions of a surface of the shaping layer such that the plurality of impact absorbing parts are held by the shaping layer in a predetermined relative arrangement.   
     
     
         2 . The impact absorbing component of  claim 1 , wherein the polymer-based material is flexible so as to permit bending of the shaping layer for moving the plurality of impact absorbing parts relative to each other. 
     
     
         3 . The impact absorbing component of  claim 1 , wherein the shaping layer comprises a hinge portion adapted to permit folding of the shaping layer so as to move the impact absorbing parts to a second configuration different from the first configuration. 
     
     
         4 . The impact absorbing component of  claim 1 , wherein the plurality of impact absorbing parts comprises first, second and third impact absorbing parts, and wherein the shaping layer comprises:
 a first hinge portion between the first and second impact absorbing parts and adapted to permit folding of the shaping layer so as to move the first and second impact absorbing parts relative to each other; and   a second hinge portion between the second and third impact absorbing parts and adapted to permit folding of the shaping layer so as to move the second and third impact absorbing parts relative to each other.   
     
     
         5 . The impact absorbing component of  claim 1 , wherein the impact absorbing parts comprise expanded polystyrene. 
     
     
         6 . The impact absorbing component of  claim 1 , wherein the polymer-based material comprises polyurethane. 
     
     
         7 . The impact absorbing component of  claim 1 , wherein, in the predetermined relative arrangement, the impact absorbing parts are spaced apart by a distance in the range of 5 mm to 100 mm. 
     
     
         8 . The impact absorbing component of  claim 7 , wherein the distance is in the range of 5 mm to 25 mm. 
     
     
         9 . The impact absorbing component of  claim 1 , wherein the predetermined relative arrangement is adapted so that the plurality of impact absorbing components are configured to substantially align with two separate portions of a human skull. 
     
     
         10 . A helmet comprising:
 a rigid outer shell; and   an impact absorbing component according to  claim 1  provided within the rigid outer shell.   
     
     
         11 . A method of manufacturing an impact absorbing component for a helmet, the impact absorbing component being shaped to provide protection for at least a portion of a human skull, wherein the method comprises:
 obtaining a shaping layer of polymer-based material; and   attaching a plurality of impact absorbing parts to respective portions of a surface of the shaping layer such that the plurality of impact absorbing parts are held by the shaping layer in a predetermined relative arrangement.   
     
     
         12 . The method of  claim 11 , wherein attaching a plurality of impact absorbing parts to respective portions of a surface of the shaping layer comprises:
 overmolding the plurality of impact absorbing parts with the shaping layer of polymer-based material to form a single impact absorbing component.   
     
     
         13 . The method of  claim 11 , wherein the shaping layer comprises a hinge portion adapted to permit folding of the shaping layer so as to move the impact absorbing parts to second configuration different from the first configuration. 
     
     
         14 . The method of  claim 11 , wherein the plurality of impact absorbing parts comprises first, second and third impact absorbing parts, and wherein the shaping layer comprises:
 a first hinge portion between the first and second impact absorbing parts and adapted to permit folding of the shaping layer so as to move the first and second impact absorbing parts relative to each other; and   a second hinge portion between the second and third impact absorbing parts and adapted to permit folding of the shaping layer so as to move the second and third impact absorbing parts relative to each other.   
     
     
         15 . The method of  claim 11 , wherein attaching a plurality of impact absorbing parts to respective portions of a surface of the shaping layer comprises: spacing the impact absorbing parts apart by a distance in the range of 5 mm to 100 mm. 
     
     
         16 . The method of  claim 15 , wherein the distance is in the range of 5 mm to 25 mm. 
     
     
         17 . A method of manufacturing a helmet comprising:
 manufacturing an impact absorbing component for a helmet according to  claim 11 ; and fixing the impact absorbing component within a rigid outer shell.