Protective shell construction and method

Abstract

A shell for protective equipment having a rigid outer layer defining an outer surface suitable for directly receiving a surface finish thereon, an inner layer having a higher impact resistance than the outer layer, and an intermediate layer sandwiched between the outer and inner layers, the intermediate layer forming a bond with the inner and outer layers. Also, there is provided a protective element comprising rigid inner and outer layer, and an intermediate layer sandwiched between the outer and inner layers, the intermediate later absorbing part of an energy produced upon an impact on the outer surface of the outer layer. Further, there is provided a method of manufacturing a shell for protective equipment.

1 . A shell for protective equipment comprising:
 a rigid outer layer defining an outer surface suitable for directly receiving a surface finish thereon;   an inner layer having a higher impact resistance than the outer layer; and   an intermediate layer sandwiched between the outer and inner layers, the intermediate layer forming a bond with the inner and outer layers.   
   
   
       2 . The protective shell according to  claim 1 , wherein the intermediate layer is more flexible than the inner and outer layers. 
   
   
       3 . The protective shell according to  claim 1 , wherein the outer layer includes a thermoplastic material. 
   
   
       4 . The protective shell according to  claim 1 , wherein the inner layer includes at least one of polyethylene fibers, vinylon fibers, fiberglass, carbon fibers, aramid fibers and basalt fibers. 
   
   
       5 . The protective shell according to  claim 1 , wherein the intermediate layer includes a polymer film. 
   
   
       6 . The protective shell according to  claim 5 , wherein the polymer film is one of a polyamide copolymer and an urethane blend copolymer. 
   
   
       7 . A protective element comprising:
 a rigid outer layer defining an aesthetic outer surface;   an inner layer having a higher impact resistance than the outer layer; and   an intermediate layer sandwiched between the outer and inner layers, the intermediate layer absorbing part of an energy produced upon an impact on the outer surface of the outer layer.   
   
   
       8 . The protective element according to  claim 7 , further comprising a padding layer connected to at least portions the inner layer opposite of the intermediate layer. 
   
   
       9 . The protective element according to  claim 7 , wherein the outer layer includes a thermoplastic material. 
   
   
       10 . The protective element according to  claim 7 , wherein the inner layer includes at least one of polyethylene fibers, vinylon fibers, fiberglass, carbon fibers, aramid fibers and basalt fibers. 
   
   
       11 . The protective shell according to  claim 7 , wherein the intermediate layer includes a polymer film. 
   
   
       12 . The protective shell according to  claim 11 , wherein the polymer film is one of a polyamide copolymer and an urethane blend copolymer. 
   
   
       13 . The protective shell according to  claim 7  wherein the intermediate layer forms a bond with the inner and outer layers. 
   
   
       14 . A method of manufacturing a shell for protective equipment, the method comprising:
 preforming a rigid outer layer to a desired shape of the shell;   bonding an intermediate layer to the outer layer, the outer layer including a material adapted to bond with a selected curable material;   placing the outer and intermediate layers in a female support having the desired shape of the shell, the outer layer lying against the support;   placing a layer of fiber material over the intermediate layer;   providing the selected curable material in contact with the layer of fiber material; and   applying pressure on the curable material and layer of fiber material to flow the curable material within the layer of fiber material, cure the curable material and bond the curable material with the intermediate layer.   
   
   
       15 . The method according to  claim 14 , wherein the steps of preforming the rigid outer layer and bonding the intermediate layer to the outer layer are performed simultaneously. 
   
   
       16 . The method according to  claim 15 , wherein the steps of preforming the rigid outer layer and bonding the intermediate layer are performed through a vacuum molding process. 
   
   
       17 . The method according to  claim 14 , wherein the layer of fiber material is preformed before being applied over the intermediate layer. 
   
   
       18 . The method according to  claim 14 , wherein the pressure is applied by inflating a bladder complementary to the support to press the bladder against the layer of fiber material. 
   
   
       19 . The method according to  claim 14 , further comprising heating the curable material while applying the pressure. 
   
   
       20 . The method according to  claim 19 , wherein the pressure and heat are applied by inflating a bladder complementary to the support to press the bladder against the layer of fiber material, the bladder being inflated by flowing pressurized hot water therein.