In-molded helmet chinbar

Abstract

A helmet includes a shell having an interior surface, a padding disposed along the interior surface of the shell, and a chinbar. The padding defines a first engagement surface positioned at a first lateral side of the padding and a second engagement surface positioned at an opposing second lateral side of the padding. The chinbar includes a cage, a first flange, and a second flange. The cage includes a first end defining a third engagement surface and a second end defining a fourth engagement surface. The third engagement surface interfaces with the first engagement surface and the fourth engagement surface interfaces with the second engagement surface. The first flange extends from the first end of the cage. The second flange extends from the second end of the cage. The first flange and the second flange of the chinbar are embedded within the padding.

1 . A helmet, comprising:
 a shell having a front opening;   a padding disposed along an interior surface of the shell, the padding having a first lateral side portion and a second lateral side portion;   a chinbar coupled to the shell, the chinbar extending around the front opening and a lower portion of a wearer's head when the helmet is worn, the chinbar defining a first flange and a second flange, the first and second flanges having flange apertures extending therethrough,   wherein the first flange is embedded within the first lateral side portion of the padding and the second flange is embedded within the second lateral side portion of the padding and the padding extends through the flange apertures.   
     
     
         2 . The helmet of  claim 1 , wherein the padding comprises (i) an outer layer coupled to the interior surface of the shell and molded over the first flange and the second flange, and (ii) an inner layer configured to conform to the head of the wearer. 
     
     
         3 . The helmet of  claim 2 , wherein the outer layer includes a first material having a first density, and the inner layer includes a second material different from the first material. 
     
     
         4 . The helmet of  claim 1 , wherein the chinbar includes a chinbar exterior surface, wherein the first and second flange each includes a flange exterior surface, and wherein the flange exterior surface is offset toward an interior of the helmet from the chinbar exterior surface. 
     
     
         5 . The helmet of  claim 1 , wherein the first flange extends from a first end of the chinbar, and wherein the second flange extends from a second end of the chinbar. 
     
     
         6 . The helmet of  claim 1 , wherein the chinbar is coupled to the shell by a fastener extending through coaxially aligned holes in the shell and the chinbar. 
     
     
         7 . The helmet of  claim 6  comprising a first fastener extending through holes in a first side of the shell and the first flange and a second fastener extending through holes in a second side of the shell and the second flange. 
     
     
         8 . The helmet of  claim 1 , wherein the chinbar comprises a cage. 
     
     
         9 . The helmet of claim  9 , wherein the first flange comprises a first plate and a first rim that extends around the first plate and the second flange comprises a second plate and a second rim that extends around the second plate. 
     
     
         10 . A helmet, comprising:
 a shell;   a chinbar coupled to the shell and extending around a lower portion of a wearer's head when the helmet is worn, the chinbar and the shell defining a front opening;   a padding disposed along an interior surface of the shell, the padding including a side portion configured to be positioned adjacent to a side of a head of a wearer and defining a chinbar engagement surface, wherein   the chinbar comprises a padding engagement surface conforming with the chinbar engagement surface, the chinbar including a flange extending through the chinbar engagement surface and with a flange aperture extending therethrough, wherein the flange is embedded within the side portion of the padding.   
     
     
         11 . The helmet of  claim 10 , wherein the padding includes (i) an outer layer attached to the shell and molded over the flange, and (ii) an inner layer adjacent to the outer layer and configured to conform to the head of a wearer. 
     
     
         12 . The helmet of  claim 11 , wherein the outer layer includes a first material having a first density, and the inner layer includes a second material different from the first material. 
     
     
         13 . The helmet of  claim 10 , wherein the flange defines a plurality of apertures, and wherein a portion of the padding extends through the apertures. 
     
     
         14 . The helmet of  claim 10 , wherein the flange defines a plurality of fingers that fan out within the padding. 
     
     
         15 . The helmet of  claim 10 , wherein the chinbar is secured to the shell by a fastener extending through coaxially aligned holes in the shell and the chinbar. 
     
     
         16 . The helmet of  claim 10 , wherein the chinbar comprises a cage. 
     
     
         17 . The helmet of  claim 10 , wherein the first flange comprises a first plate and a first rim that extends around the first plate and the second flange comprises a second plate and a second rim that extends around the second plate. 
     
     
         18 . A helmet, comprising:
 a shell having a front opening;   a chinbar comprising a cage extending around the front opening and a lower portion of a wearer's head when the helmet is worn, the chinbar comprising a first flange extending from a first interface and a second flange extending from a second interface, the first and second flanges having flange apertures extending therethrough,   a padding disposed along an interior surface of the shell, the padding having a first lateral side portion and a second lateral side portion;   wherein the first flange is embedded within the first lateral side portion of the padding and the second flange is embedded within the second lateral side portion of the padding and the padding extends through the flange apertures;   wherein the chinbar is coupled to the shell with a first fastener extending through coaxially aligned holes in a first side of the shell and the first interface and a second fastener extending through coaxially aligned holes in a second side of the shell and the second interface.   
     
     
         19 . The helmet of  claim 18 , wherein the padding includes (i) an outer layer attached to the shell and molded over the flange, and (ii) an inner layer adjacent to the outer layer and configured to conform to the head of a wearer. 
     
     
         20 . The helmet of  claim 18 , wherein the first flange comprises a first plate and a first rim that extends around the first plate and the second flange comprises a second plate and a second rim that extends around the second plate.