Multi-body helmet construction and strap attachment method
A helmet may include an upper-body comprising a first outer shell coupled to a first energy-absorbing shell formed of expanded polypropylene (EPP), expanded polystyrene (EPS), expanded polyurethane (EPU), or expanded polyolefin (EPO). A lower-body may include a second outer shell coupled to a second energy-absorbing shell formed of EPP, EPS, EPU, or EPO, wherein an upper portion of the lower-body is nested within the upper-body and a lower portion of the lower-body extends to an outer surface of a lower portion of the upper-body. A strap anchor may be disposed between the upper-body and the lower-body, and be sandwiched between the upper-body and the lower-body with the strap anchor being adjacent to, and oriented towards, the lower-body. A strap may be coupled to the fastening device and coupled to the strap anchor for coupling the helmet to a head of a user.
1. A helmet comprising:
an upper-body comprising a first outer shell coupled to a first energy-absorbing shell;
a lower-body comprising a second outer shell separate from the first outer shell and coupled to a second energy-absorbing shell separate from the first energy-absorbing shell, wherein an upper-portion of the lower body is nested within and substantially coextensive with the upper-body;
a strap anchor disposed between the upper-body and the lower-body, the strap anchor comprising a housing with an opening formed through the housing and sized to receive a fastening device through the opening, wherein the strap anchor is sandwiched between the upper-body and the lower-body with the strap anchor being adjacent to, and oriented towards, the lower-body; and
a strap coupled to the fastening device and coupled to the strap anchor, wherein the strap extends between the upper-body and the lower-body for coupling the helmet to a head of a user.
2. The helmet of claim 1 , wherein the first energy-absorbing shell is formed of expanded polypropylene (EPP), expanded polystyrene (EPS), expanded polyurethane (EPU), or expanded polyolefin (EPO).
3. The helmet of claim 1 , wherein the second energy-absorbing shell is formed of EPP, EPS, EPU, or EPO.
4. The helmet of claim 1 , wherein the strap anchor comprises a height, width, and depth less than or equal to at least one of 10-30 millimeters (mm), by 10-50 mm, and by 2-10 mm.
5. The helmet of claim 1 , wherein:
the strap anchor is formed without a web; and
the strap anchor is sandwiched between the upper-body and the lower-body and hidden from view within the helmet.
6. The helmet of claim 1 , wherein the strap anchor is disposed within the upper-body such that the strap anchor opening is substantially coplanar with an inner surface of the upper-body and offset from a lower edge of the upper-body.
7. The helmet of claim 1 , wherein:
the first energy-absorbing material hasving a density in a range of 70-100 g/L; and
the second energy-absorbing material hasving a density in a range of 50-80 g/L.
8. The helmet of claim 1 , wherein:
the fastening device comprises a rod defining a length L; and
the opening defines a first width W 1 greater than the length L, and a second width W 2 less than the length L.
9. The helmet of claim 1 , wherein the one of the inner surface of the upper-body and the outer surface of the lower-body define one or more bumps configured to be mateably coupled with one or more indents in the other of the inner surface of the upper-body and the outer surface of the lower-body.
10. A helmet comprising:
an upper-body comprising a first outer shell coupled to a first energy-absorbing shell;
a lower-body comprising a second outer shell separate from the first outer shell and coupled to a second energy-absorbing shell separate from the first energy-absorbing shell, nested within and substantially coextensive with the upper-body;
a strap anchor disposed in the upper-body and comprising a housing defining an opening formed through the housing and sized to receive a fastening device through the opening, wherein the strap anchor is adjacent to, and oriented towards, the lower-body; and
a strap coupled to the fastening device and coupled to the strap anchor, wherein the strap extends between the upper-body and the lower-body for coupling the helmet to a head of a user.
11. The helmet of claim 10 , wherein the first energy-absorbing shell is formed of expanded polypropylene (EPP), expanded polystyrene (EPS), expanded polyurethane (EPU), or expanded polyolefin (EPO).
12. The helmet of claim 10 , wherein the second energy-absorbing shell is formed of EPP, EPS, EPU, or EPO.
13. The helmet of claim 10 , wherein the strap anchor comprises a height, width, and depth less than or equal to at least one of 10-30 millimeters (mm), by 10-50 mm, and by 2-10 mm.
14. The helmet of claim 10 , wherein:
the strap anchor is formed without a web; and
the strap anchor is sandwiched between the upper-body and the lower-body and hidden from view within the helmet.
15. The helmet of claim 10 , wherein the strap anchor is disposed within the upper-body such that the strap anchor opening is substantially coplanar with an inner surface of the upper-body and offset from a lower edge of the upper-body.
16. The helmet of claim 10 , wherein:
the first energy-absorbing material has a density in a range of 70-100 g/L; and
the second energy-absorbing material has a density in a range of 50-80 g/L.
17. The helmet of claim 10 , wherein the fastening device comprises a rod.
18. The helmet of claim 17 , wherein the rod defines a length L; and
the opening defines a first width W 1 greater than the length L, and a second width W 2 less than the length L.
19. The helmet of claim 10 , wherein the one of the inner surface of the upper-body and the outer surface of the lower-body define one or more bumps configured to be mateably coupled with one or more indents in the other of the inner surface of the upper-body and the outer surface of the lower-body.
20. The helmet of claim 10 , further comprising a cover coupled to the strap anchor.