# US 12,214,531 B2 · Mold for the manufacture of sporting helmets and relative process for molding such sporting helmets

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 12,214,531 B2
- Document ID: US12214531B2
- Status: Granted
- Kind: B2
- Application number: 17/645,332
- Filed: 2021-12-21
- Published: 2022-06-30
- Granted: 2025-02-04
- Earliest claimed: 2020-12-31
- Assignees: Kask S.P.A.
- Applicants: Kask S.P.A.
- Inventors: Angelo Gotti
- Web page: https://patentgrep.com/patent/US12214531B2

## CPC

- B29C 45/2602: {Mould construction elements}
- A42C 2/002: {In-mould forming}
- B29C 31/008: {Handling preformed parts, e.g. inserts (B29C37/001 takes precedence; for injection moulding B29C45/14008; for blow moulding B29C49/2408; for thermoforming B29C51/165)}
- B29C 44/12: Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
- B29C 45/14008: {Inserting articles into the mould (B29C45/14827 takes precedence)}
- B29C 45/14065: {Positioning or centering articles in the mould}
- B29C 45/64: Mould opening, closing or clamping devices {(combined with means for plasticising or homogenising B29C45/70)}
- B29C 44/3426: {Heating by introducing steam in the mould}
- B29C 44/445: {in the form of expandable granules, particles or beads}
- B29K 2025/06: {PS, i.e. polystyrene}
- B29L 2031/4821: {Helmets}
- B29L 2031/52: Sports equipment {; Games; Articles for amusement}; Toys (B29L2031/54 takes precedence)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- A42C: MANUFACTURING OR TRIMMING HEAD COVERINGS, e.g. HATS
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

A mold and a relative molding process for the manufacture of sporting helmets, in particular cycling helmets. The mold includes a frame provided with at least one molding concavity; a counter frame engageable to the frame to hermetically close the respective molding concavity and allow the execution of at least one molding cycle. The mold further includes at least one intermediate support element for supporting and positioning one or more components of the sporting helmet to be manufactured inside the respective molding concavity of the frame. The intermediate support element is kept inside the respective molding concavity during the entire molding cycle in order to keep the components of the sporting helmet to be manufactured in their assigned positions.

## Claims

### Claim 1

A mold for the manufacture of sporting helmets, the mold comprising:
at least one frame defining at least one molding concavity, for molding at least one respective sporting helmet;
at least one counter frame engageable to the frame to hermetically close the respective molding concavity and allow an execution of at least one molding cycle;
wherein the mold comprises at least one intermediate support element for supporting and positioning one or more components of the sporting helmet to be made inside the respective molding concavity of the frame, the intermediate support element having:
a first portion arranged to receive in engagement one or more components of the sporting helmet to be manufactured according to respective predetermined positions;
a second portion facing away from the first portion and having at least one grip handle, for manual positioning of the intermediate support element in the respective molding concavity of the frame and a consequent positioning of the components of the sporting helmet to be manufactured inside said molding concavity, the second portion of the intermediate support element being arranged to be coupled to the respective counter frame;
at least one engagement member for a stable coupling of the intermediate support element to the frame inside the respective molding concavity, the engagement member being operatively interposed between the intermediate support element and the respective molding concavity of the frame;
at least one engagement constraint for the stable coupling of the intermediate support element to the counter frame, the engagement constraint being operationally interposed between the intermediate support element and the counter frame.

### Claim 2 (depends on 1)

The mold according to claim 1, wherein the intermediate support element comprises a substantially annular structure having internally at least one seat and/or one relief for supporting at least one component of the sporting helmet to be manufactured, the support seat and/or relief being accessible from the first portion.

### Claim 3 (depends on 2)

The mold according to claim 2, wherein the engagement member comprises:
at least one locking seat, realized outside the annular structure of the intermediate support element;
at least one locking protuberance, movable within the respective molding concavity of the frame between a rest position wherein the intermediate support element can be inserted into the molding concavity or removed therefrom and a locking position wherein the locking protuberance engages the respective locking seat of the intermediate support element to hold the latter inside the respective molding concavity of the frame.

### Claim 4 (depends on 3)

The mold according to claim 3, wherein the locking protuberance can be controlled with an actuation device located outside the mold.

### Claim 5 (depends on 2)

The mold according to claim 2, wherein the engagement constraint comprises at least one coupling lug and at least one coupling seat operatively interposed between the intermediate support element and the counter frame.

### Claim 6 (depends on 5)

The mold according to claim 5, wherein the engagement constraint comprises:
at least one coupling lug, protruding externally from the annular structure of the intermediate support element;
at least one coupling seat, realized on the counter frame, the coupling lug and the respective coupling seat being at least partly countershaped to ensure a stable coupling between the intermediate support element and the respective counter frame.

### Claim 7 (depends on 6)

The mold according to claim 6, wherein the locking seat of the locking member is externally realized on a respective coupling lug of the engagement constraint.

### Claim 8 (depends on 2)

The mold according to claim 2, wherein the grip handle is defined by the annular structure of the intermediate support element.

### Claim 9 (depends on 2)

The mold according to claim 2, wherein the grip handle includes a gripping portion defined by a block engaged to the annular structure of the intermediate support element, the gripping portion being designed to be manually gripped by an operator.

### Claim 10 (depends on 2)

The mold according to claim 2, wherein the grip handle includes a gripping opening defined between the annular structure of the intermediate support element and the gripping portion of the gripping handle to allow the insertion of a hand of an operator when he has to grasp said handle.

### Claim 11 (depends on 1)

The mold according to claim 1, wherein the mold comprises at least one auxiliary support element identical to the intermediate support element, the auxiliary support element being usable to prepare one or more components of a sporting helmet to be molded while the intermediate support element is engaged in the respective molding concavity of the frame of the mold during a relative molding cycle.

### Claim 12 (depends on 10)

The process according to claim 10, further comprising the steps of:
preparing at least one auxiliary support element identical to the intermediate support element;
positioning one or more components of the sporting helmet to be manufactured on a first portion of the auxiliary support element according to respective predetermined positions, during a molding cycle wherein the intermediate support element is located within the respective molding concavity of the mold frame;
positioning the auxiliary support element within the respective molding concavity of the mold frame with the first portion facing said molding concavity to position the components of the sporting helmet to be manufactured in the respective molding concavity according to respective predetermined positions, after the removal of the intermediate support element from said molding concavity of the frame of the mold;
blocking the auxiliary support element inside the respective molding concavity;
engaging the counter frame of the mold on the frame of the same to hermetically close the respective molding concavity at a second portion of the auxiliary support element opposite with respect to the first portion;
starting a molding cycle by injecting a corresponding molding material.

### Claim 13 (depends on 12)

The process according to claim 12, wherein the steps of:
separating the intermediate support element from the respective manufactured sporting helmet; and,
positioning one or more components of a subsequent sporting helmet to be manufactured in the first portion of the intermediate support element according to respective predetermined positions for a new molding cycle to be carried out, are carried out while the auxiliary support element is located within the respective molding concavity during the respective molding cycle.

### Claim 14

A process for molding sporting helmets, in particular cycling helmets, comprising the steps of:
providing at least one frame of a mold defining at least one molding concavity, for molding at least one respective sporting helmet;
preparing at least one counter frame of the mold engageable to the frame to hermetically close the respective molding concavity and allowing an execution of at least one molding cycle;
preparing at least an intermediate support element for supporting and positioning one or more components of the sporting helmet to be manufactured inside the respective molding concavity of the frame of the mold;
placing one or more components of the sporting helmet to be manufactured in a first portion of the intermediate support element according to respective predetermined positions;
positioning the intermediate support element inside the respective molding concavity of the mold frame with the first portion facing said molding concavity to position the components of the sporting helmet to be manufactured in the respective molding concavity according to respective predetermined positions;
blocking the intermediate support element inside the respective molding concavity according to the previously determined position;
engaging the counter frame of the mold to the frame of the same to hermetically close the respective molding concavity in correspondence with a second portion of the intermediate support element opposite the first portion;
starting a molding cycle by injecting a corresponding molding material;
disengaging the counter frame of the mold from the frame of the same to access the respective molding concavity and the respective intermediate support element, when the molding cycle is completed;
releasing the intermediate support element from the respective molding concavity;
removing the intermediate support element from the respective molding concavity of the frame of the mold together with the respective manufactured sporting helmet;
separating the intermediate support element from the respective manufactured sporting helmet;
repeating the process again.

### Claim 15 (depends on 14)

The method according to claim 14, wherein the step of positioning the intermediate support element in the respective molding concavity and the step of removing the intermediate support element together with the respective sporting helmet manufactured by the respective molding concavity are carried out manually, by gripping at least one grip handle defined in correspondence with the second portion of the intermediate support element.

### Claim 16 (depends on 15)

The process according to claim 15, wherein;
the step of positioning the intermediate support element in the respective molding concavity is carried out by inserting said intermediate support element in the respective molding concavity along a direction substantially orthogonal with respect to a main lying plane of the frame of the mold;
the step of removing the intermediate support element together with the respective sporting helmet manufactured by the respective molding concavity is carried out by extracting said intermediate support element along a direction substantially orthogonal to the main lying plane of the mold frame.

### Claim 17 (depends on 14)

The process according to claim 14, wherein a step of locking the intermediate support element inside the respective molding concavity of the mold frame and a step of unlocking of the intermediate support element from the respective molding concavity of the mold frame are carried out by an interaction between at least one movable locking protuberance, arranged in the molding concavity, and at least one locking seat realized externally on the intermediate support element.

### Claim 18 (depends on 17)

The process according to claim 17, wherein:
the step of locking the intermediate support element in the respective molding concavity of the frame of the mold is carried out by activating the locking protuberance from a rest position wherein the element support intermediate can be inserted into the molding concavity or removed therefrom and a locking position wherein the locking protuberance engages the respective locking seat of the intermediate support element holding the latter inside the respective molding concavity of the mold frame;
the step of unlocking the intermediate support element from the respective molding concavity is carried out by moving the locking protuberance from the locking position to the rest position.

### Claim 19 (depends on 18)

The process according to claim 18, wherein the locking step and the unlocking step are carried out by movement operating the locking protuberance by operating a control device located externally to the mold by operating of a control pedal.

### Claim 20 (depends on 14)

The process according to claim 14, wherein:
the step of engaging the counter frame of the mold to the frame of the same is also carried out by engaging at least one coupling lug externally projecting from the intermediate support element in at least one coupling seat realized on the counter frame of the mold;
the step of disengaging the counter frame of the mold from the frame of the same is also performed by disengaging the coupling lug protruding externally from the intermediate support element from the respective coupling seat realized on the counter frame of the mold.