Partial Outer Hard Shell Helmet with Fiber Filled Plastic

Abstract

A helmet may include a helmet body with a plurality of spars separated from each other by a plurality of channels extending from an inner surface of the helmet body to an outer surface of the helmet body, the spars formed primarily of a foamed energy management material. Each of the plurality of spars is separated from at least one adjacent spar of the plurality of spars by a different one of the plurality of channels having a width no greater than 30 mm. At least two spars are separated from each other by an enlarged channel having a width greater than at least 60 mm. At least one shell segment formed of a fiber filled plastic is directly coupled around a majority of its border to the at least two spars separated by the enlarged channel and spanning the enlarged channel.

Description

RELATED APPLICATIONS

This application is based on, claims priority to, and incorporates herein by reference in its entirety, U.S. Provisional Patent Application Ser. No. 62/417,959, filed on Nov. 4, 2016, and entitled “Partial Outer Hard Shell Helmet with Fiber Filled Plastic.”

TECHNICAL FIELD

Aspects of this document relate generally to a helmet with a partial hard outer shell, and more specifically to a helmet with a fiber filled plastic used in the partial hard outer shell.

BACKGROUND

Protective headgear and helmets have wide uses. Different helmets come in different sizes and generally include comfort padding inside the helmet. To meet safety standards, certain coverage of the head area by protective materials is required. However, because helmets often get hot inside, air flow vents that extend through the protective material and allow ambient air to flow through the helmet or come in contact with the wearer's head are sometimes used in helmet designs, particularly sporting helmet designs. Other than the shape of the inside surface and comfort padding for the helmet generally having an inside surface that is sized to receive a head, and a fit system designed to keep the helmet close to the wearer's head, helmets do not have other accommodating structures inside the helmet to make wearing the helmet more comfortable for particular users.

Outer shells of safety helmets generally include protective outer shell wherever there is a protective inner layer of material, or at least the vast majority of the surface area of the outer shell has at least one layer of protective material immediately inside the protective outer layer. For typical road cycling helmets, different from off-road cycling helmets, hard shell protective outer layers are not generally used, but a thin layer of decorative plastic is included over the inner layer of protective material, and the inner layer of protective material is often in-molded into or later adhered to the outer shell or shell parts that cover the inner layer of protective material.

SUMMARY

According to an aspect of the disclosure, a helmet may comprise a helmet body comprising a plurality of spars coupled together at a front end of the helmet body and at a rear end of the helmet body, the spars separated from each other between the front end and the rear end by a plurality of channels extending from an inner surface of the helmet body to an outer surface of the helmet body, the spars formed primarily of a foamed energy management material, wherein each of the plurality of spars is separated from at least one adjacent spar of the plurality of spars by a different one of the plurality of channels having a width no greater than 30 mm, measured as a maximum channel width between two immediately adjacent spars; and wherein at least two spars of the plurality of spars are separated from each other by an enlarged channel, of the plurality of channels, the enlarged channel having a width greater than at least 60 mm, measured as a maximum channel width between two immediately adjacent spars of the plurality of spars, and at least one shell segment formed of a fiber filled plastic and directly coupled around a majority of its border to the at least two spars separated by the enlarged channel and spanning the enlarged channel such that the enlarged channel is beneath the at least one shell segment.

Particular embodiments may comprise one or more of the following. The at least one shell segment may comprise at least two shell segments, symmetrically positioned on opposing sides of the helmet. The enlarged channel may comprise a first enlarged channel and the helmet further comprising a second enlarged channel of the plurality of channels, the second enlarged channel having a width greater than at least 60 mm, measured as a maximum channel width between two immediately adjacent spars of the plurality of spars, wherein the at least one shell segment comprises first and second shell segments not connected to each other except through the energy management material, the first shell segment positioned over the first enlarged channel and the second shell segment positioned over the second enlarged channel. The first and second shell segments may each comprise at least one air vent extending through the respective shell segment. Each of the first and second shell segments may be in-molded into the energy management material of the spars about the majority of the respective borders of the first and second shell segments. The at least one shell segment may comprise at least one air vent extending through the shell segment. The energy management material is at least one of EPS and EPP. The at least one shell segment is in-molded into the energy management material of the spars about the majority of the border of the at least one shell segment. The at least one shell segment formed of the fiber filled plastic is formed of a fiber filled thermoplastic comprising fibers longer than 0.5 inches and a fiber fill between 20% and 60%.

According to an aspect of the disclosure, a bicycle helmet may comprise a helmet body comprising a plurality of spars separated from each other by a plurality of channels extending from an inner surface of the helmet body to an outer surface of the helmet body, the spars formed primarily of a foamed energy management material, wherein a first set of channels of the plurality of channels each comprises a channel opening sized so that a sphere having a radius of 15 mm cannot pass through the channel from outside the helmet body to inside the helmet body without contacting a side of the channel, and at least an enlarged channel of the plurality of channels comprises a channel opening sized so that the sphere having the radius of 15 mm can pass through the channel from outside of the helmet body to inside the helmet body without contacting a side of the channel, and at least one shell formed of a fiber filled plastic and directly coupled around a majority of its border to at least two spars bordering the enlarged channel and spanning the enlarged channel such that the enlarged channel is beneath the at least one shell.

Particular embodiments may comprise one or more of the following. The at least one shell may comprise at least two shells, symmetrically positioned on opposing sides of the helmet. The enlarged channel may comprise a first enlarged channel and the helmet further comprising a second enlarged channel of the plurality of channels, the second enlarged channel having a channel opening sized so that the sphere having the radius of 15 mm can pass through the channel from outside of the helmet body to inside the helmet body without contacting a side of the second enlarged channel between two immediately adjacent spars of the plurality of spars, wherein the at least one shell comprises first and second shells not connected to each other except through the energy management material, the first shell positioned over the first enlarged channel and the second shell positioned over the second enlarged channel. The first and second shells may each comprise at least one air vent extending through the respective shell and each of the first and second shells are in-molded into the energy management material of the spars about a majority of respective borders of the first and second shells. The energy management material is EPS. The at least one shell formed of the fiber filled plastic is formed of a fiber filled thermoplastic comprising fibers longer than 0.5 inches and a fiber fill between 20% and 60%. The at least one shell segment may comprise at least one air vent extending through the shell segment. The energy management material is at least one of EPS and EPP.

Aspects, embodiments and applications of the disclosure presented here are described below in the drawings and detailed description. Unless specifically noted, it is intended that the words and phrases in the specification and the claims be given their plain, ordinary, and accustomed meaning to those of ordinary skill in the applicable arts. The inventors are fully aware that they can be their own lexicographers if desired. The inventors expressly elect, as their own lexicographers, to use only the plain and ordinary meaning of terms in the specification and claims unless they clearly state otherwise and then further, expressly set forth the “special” definition of that term and explain how it differs from the plain and ordinary meaning. Absent such clear statements of intent to apply a “special” definition, it is the inventors' intent and desire that the simple, plain and ordinary meaning to the terms be applied to the interpretation of the specification and claims.

The inventors are also aware of the normal precepts of English grammar. Thus, if a noun, term, or phrase is intended to be further characterized, specified, or narrowed in some way, such noun, term, or phrase will expressly include additional adjectives, descriptive terms, or other modifiers in accordance with the normal precepts of English grammar. Absent the use of such adjectives, descriptive terms, or modifiers, it is the intent that such nouns, terms, or phrases be given their plain, and ordinary English meaning to those skilled in the applicable arts as set forth above.

Further, the inventors are fully informed of the standards and application of the special provisions of 35 U.S.C. § 112, ¶ 6. Thus, the use of the words “function,” “means” or “step” in the Detailed Description or Description of the Drawings or claims is not intended to somehow indicate a desire to invoke the special provisions of 35 U.S.C. § 112, ¶ 6, to define the invention. To the contrary, if the provisions of 35 U.S.C. § 112, ¶ 6 are sought to be invoked to define the inventions, the claims will specifically and expressly state the exact phrases “means for” or “step for”, and will also recite the word “function” (i.e., will state “means for performing the function of [insert function]”), without also reciting in such phrases any structure, material or act in support of the function. Thus, even when the claims recite a “means for performing the function of . . . “or “step for performing the function of . . . ,” if the claims also recite any structure, material or acts in support of that means or step, or that perform the recited function, then it is the clear intention of the inventors not to invoke the provisions of 35 U.S.C. § 112, ¶ 6. Moreover, even if the provisions of 35 U.S.C. § 112, ¶ 6 are invoked to define the claimed aspects, it is intended that these aspects not be limited only to the specific structure, material or acts that are described in the preferred embodiments, but in addition, include any and all structures, materials or acts that perform the claimed function as described in alternative embodiments or forms of the disclosure, or that are well known present or later-developed, equivalent structures, material or acts for performing the claimed function.

The foregoing and other aspects, features, and advantages will be apparent to those artisans of ordinary skill in the art from the DESCRIPTION and DRAWINGS, and from the CLAIMS.

BRIEF DESCRIPTION OF THE DRAWINGS

Implementations will hereinafter be described in conjunction with the appended drawings, where like designations denote like elements, and:

FIG. 1 is a side view of a bicycle helmet with fiber filled shells;

FIG. 2 is a front perspective view of the bicycle helmet of FIG. 1 with the fiber-filled shells separated to show the enlarged channels beneath.

DETAILED DESCRIPTION

Protective headgear and helmets have been used in a wide variety of applications and across a number of industries, including recreation, sports, athletics, construction, mining, and military defense, to prevent damage to users' heads and brains. Damage and injury to a user can be prevented or reduced by preventing hard objects, sharp objects, or both, from directly contacting the user's head, and also by absorbing, distributing, or otherwise managing energy of an impact between the object and the user's head. Straps or webbing are typically used to allow a user to releasably wear the helmet, and to ensure the helmet remains on the user's head during an impact.

Helmets function to provide protection while minimizing interference with an activity. The shape of a helmet may be adapted to provide both protection and comfort (e.g. ventilation and size). Some helmets are made of two or more bodies of energy-absorbing material to form shapes that would be difficult, if not impossible, to achieve in a single molded piece.

Conventional helmets have dealt with variations in the size and shape of heads by providing different helmet sizes and fit systems. However, variations in hair length are problematic. Conventional helmets do not work well with long hair. Specifically, long hair tends to fill the internal channels and vent spaces that facilitate ventilation, a major factor in user comfort. Increasing the size of the vent spaces to allow for long hair may reduce the protection provided by the helmet. Various safety standards and certifications put limits on the size of openings that expose the head. Increasing the size of the helmet may allow internal space for longer hair, but at the cost of protection, form factor, and overall comfort. A larger helmet to accommodate for bulky hair may shift around during use, or worse, during an impact.

Contemplated in this disclosure is a partial outer hard shell helmet with fiber filled plastic. Omitting sections of energy-absorbing material where it would generally be found in a comparable helmet creates open spaces where cool air can pass over a longhaired user's head, and where the hair can expand into to free up space elsewhere in the helmet. Covering these open sections with a shell segment of fiber filled plastic maintains the protection provided by the helmet despite the missing material. By omitting sections of energy-absorbing material and using a shell segment of fiber filled plastic, a helmet may be adapted for use by a person with long hair without sacrificing protection, comfort, or form factor.

FIG. 1 depicts a side perspective view of a non-limiting embodiment of a partial outer hard shell helmet 2 with fiber filled plastic shells 4. FIG. 2 depicts a front perspective exploded view of a non-limiting embodiment of a partial outer hard shell helmet 2 with fiber filled plastic shells 4. As can be seen, the non-limiting embodiments and use cases discussed and depicted in this disclosure are directed to a bike helmet. However, it should be understood that as used herein, a helmet may comprise any helmet known in the art that might be worn by someone with long hair. Examples include, without limitation, helmets for use in athletic (professional or otherwise), recreational, and industrial settings. Furthermore, while this disclosure is focused on vented helmets, the designs and methods disclosed may also be applied to increase open areas inside non-vented helmets. Additionally, the terms “long haired” and “long hair” are being used to describe a helmet wearer whose hair tends to inhibit ventilation in traditional helmets, and should be understood to also include helmet users facing the same problem, but for other reasons (e.g. hair thickness, hair style, oddly shaped head, etc.).

As illustrated in FIGS. 1 and 2, the particular helmet 2 embodiment illustrated comprises a helmet body 4 and two partial shell segments 30. The shell segments 30 cover portions of the helmet body 4 where there is an opening that is larger than a traditional vent 22 (also called a channel 22 herein). The helmet body illustrated in FIGS. 1 and 2 can be thought of as a traditional helmet with a plurality of spars 6, 8, 10, 12, 14, 16, but with one spar missing from each side to create voids or enlarged channels 24 larger than the other traditional safety rated channels 22. As used herein, a channel is an opening that extends through the helmet body 4 from an inside surface 44 to an outside surface 46. A width 26 of a channel 22 is measured as the narrowest cross-sectional measurement of each channel 22 space for a set of width measurements for that channel taken at each shell plane between the inner 44 and outer 46 surface of the helmet body 4. The shell plane matches the shape of the inner surface 44 and each shell plane expands radially as it moves out to the outer surface 46. Thus, if a channel 22 has a measurement of 120 mm×46 mm at a first plane at a first distance from the inner surface 44 of the helmet body 4, and 100 mm×25 mm at a second plane at a second distance from the inner surface 44 of the helmet body 4, and 120 mm×20 mm at a third plane at a third distance from the inner surface 44 of the helmet body, and there are no measurements at other planes for this channel with a smaller dimension, the width 26 of the channel 22 would be 20 mm; the narrowest cross-sectional measurement of the channel space for the set of width measurements for that channel taken at each shell plane between the inner and outer surface of the helmet body. The purpose for this measurement is to determine whether the channel is small enough to withstand impacts of a particular size. If the width of the channel narrows to a point where the impacting object cannot fit through, the channel is small enough to deflect the object. If the width of the channel does not narrow enough, the impacting object can penetrate to the inner surface of the helmet through the channel. By enlarging some of the channels 28 to dimensions larger than standard safety certifications will allow, additional room is provided within the outer surface of the helmet that can accommodate a wearer's hair style or other feature of the wearer's head without compromising the safety of the helmet if the enlarged channels 28 are also covered with an appropriate shell segment 30.

The helmet spars 6, 8, 10, 12, 14, 16 are illustrated in FIGS. 1-2 as long narrow ribs of energy management material joined at least at the front end 18 and the rear end 20 of the helmet body 4 and with connectors 36 extending between them at one or more points between the front end 18 and the rear end 20. In this particular embodiment, the helmet spars 6, 8, 10, 12, 14, 16 are prominent and individually identifiable as long narrow components. In other embodiments, the spars may be configured to in more of a grid pattern with vents extending between the spars and many more connectors between the spars or with spars overlapping each other. The teachings of this disclosure apply to any helmets that have energy management material formed as an inner liner with a plurality of vents extending directly through the energy management material so that the inside of the helmet is viewable through the vents. The energy management material surrounding the vents forms the spars whether they are easily identifiable as individual spars or whether the spars overlap and merge together at places or are coupled together with connectors at more locations. The principles taught herein are not limited to modifying traditional helmet bodies, and may also be applied to helmet bodies designed specifically for use in a partial outer hard shell helmet with fiber filled plastic.

According to various embodiments, the shell segments 30 of the embodiment illustrated in FIGS. 1 and 2 contact or otherwise be bonded to the helmet body 4 at least along parts of the border 32 of the shell segments 30. See, for example, the shell segment 30 of FIG. 1, which overlaps with the helmet body 4 along the top 38 and bottom 40 edges, as well as a section near the end 42. In some embodiments, a shell segment 30 may contact the helmet body 4 in additional locations. In the event of an impact on a shell segment 30, a majority of the shell segment 30 would withstand and attenuate the force of the impact with minimal flexion, distributing the remaining impact force to the edges 38, 40 and end 42 of the shell segment 30. The shell segment 30 would then press into the helmet body 4, which would distribute and/or attenuate the remaining force. In particular embodiments, the shell segments 30 are in-molded with the foamed energy management material of the spars 6, 8, 14, 16 immediately adjacent the shell segments 30. By in-molding the shell segments 30, a majority of the borders of the shell segments 30 are embedded in the spars 6, 8, 14, 16 to provide an additional mechanical reinforcement to the shell segments 30 and to reduce the likelihood that adhesive or other coupling method will fail before the protection of the shell segment 30 is needed.

The non-limiting embodiment illustrated in FIGS. 1 and 2 has two openings or enlarged channels 24 along the sides of the helmet body covered with shell segment 30. In other embodiments, one or more covered openings may be located anywhere on the helmet body 4. Some embodiments may comprise a single shell segment 30, while others may comprise two or more. In some embodiments, a single shell segment may cover more than one opening.

As shown in FIGS. 1 and 2, the shell segments may each include one or more vents 34, and in this embodiment two vents 34, to allow air to move through the helmet body 4 enlarged channel 24 they cover. In some embodiments, the number, size, and spacing between any vents 34 in a shell segment 30 may be directed by the requirements of a safety standard or certification, as well as the mechanical properties of the shell segment 30. For example, in one test for certification against a safety standard defined in 16 CFR Part 1203, three different impact anvils are tested against the helmet surface to gauge penetration; namely, a flat anvil, a hemispherical anvil and a curbstone anvil. The flat anvil has an impact face with a minimum diameter of 125 mm and a thickness of at least 24 mm thick. The hemispherical anvil has a hemispherical impact surface with a radius of 48+/−1 mm. The curbstone anvil has two flat faces making an angle of 105 degrees meeting along a striking edge having a radius of 15 mm+/−0.5 mm; the curbstone anvil having a height not less than 50 mm and a length not less than 200 mm. Embodiments of the helmet body include sections of energy-absorbing material provided with gaps or channels large enough to not pass the requirements of the safety standards and certification standards, with those gaps then being blocked by a protective plate or shell as described herein. Other gaps or channels not blocked by a protective shell are small enough to pass the safety standards and certification standards.

According to various embodiments, a helmet body 4 may comprise one or more types of energy-absorbing material, such as expanded polystyrene (EPS), expanded polyurethane (EPU), expanded polyolefin (EPO), expanded polypropylene (EPP), or other suitable material known in the art. In some embodiments, the helmet body 4 may be without any additional shell. In other embodiments, the helmet body may further comprise its own shell, including but not limited to a layer of stamped polyethylene terephthalate (PET) or a polycarbonate shell, to which it was directly bonded (e.g. in-molded, etc.).

In order to provide effective protection, the shell 30 segments are composed of a material that is strong enough to safely withstand and attenuate forces typical to impacts associated with a particular type of helmet, according to various embodiments. Those of ordinary skill in the art of helmet safety standards and manufacture are familiar with these materials. A light, thin material that can accomplish this would be both rigid, and safe. Usually, when a plastic is very stiff, such as PET-G or ABS, and will break with sharp edges as a standard mode of failure, which could be dangerous to the helmet wearer. When the inner liner of the helmet has small openings that meet safety standards, this is less of a concern. On the other hand, plastics with elastic failure modes, such as K-resin or polycarbonate alloy, are usually too soft to effectively attenuate an impact.

In one embodiment, the shell segments 30 may be composed of carbon fiber. Carbon fiber can be very stiff, and able to attenuate a great deal of energy, while still having a safe failure mode due to the strong fibers. However, carbon fiber can be difficult and expensive to manufacture.

In other embodiments, the shell segments 30 may be composed of fiber filled plastic. Fiber filled plastic includes a thermoplastic into which fibers, such as glass fibers, have been incorporated. It may be injection-molded, yet can have strength properties on par with carbon fiber. Example base thermoplastics in a fiber filled plastic include, but are not limited to, nylon, polypropylene, polyurethane, and Eastman Tritan copolyester, and PolyOne OnForce LFT Long-Fiber Thermoplastics. By using fiber-reinforced materials, the shell segment structure is very rigid, but when it cracks, it does not produce the dangerous sharp edges of unreinforced materials. In some embodiments, the shell segments may comprise fiber filled plastic employing long fibers (e.g. fibers longer than 0.5 inches, etc.).

When ABS that is made strong and rigid enough to withstand a crash impact (e.g. 7 mm) it may crack, creating sharp edges like a knife. When carbon fiber is exposed to a crash impact, the impacted portion may turn to powder leaving the unimpacted portions unaffected. In some embodiments of the helmets 2 described herein, the fiberfill of the shell segments 30 may range from 20% to 60%. In a specific embodiment, the shell segments 30 may be composed of fiber filled plastic comprising PolyOne OnForce LFT Long Fiber Thermoplastics using a long-glass fiber filler ranging from 30% to 50% of the total volume, where 40%+/−2% of the total volume in long-glass fiber filler is particularly advantageous. As an option, the shell segments 30 may be further coated with a clear ultraviolet resistant coating.

In some embodiments, the shell segments 30 may be coupled to the helmet 2 body through in-molding. For example, in one embodiment, the shell segments 30 may be directly bonded to the helmet body 4 during molding. In another embodiment, one or more of the shell segments edges 38, 40, 42 may be sandwiched between a thin shell of the helmet body 4, such as polycarbonate, and the helmet body 4, all bonding together through in-molding. In other embodiments, the shell segments 30 may be bonded to the helmet body 4 after the helmet body 4 has been formed using adhesive or other bonding method known in the art.

It will be understood that implementations are not limited to the specific components disclosed herein, as virtually any components consistent with the intended operation of a method and/or system implementation for partial outer hard shell helmets with fiber filled plastic may be utilized. Accordingly, for example, although particular partial outer hard shell helmets with fiber filled plastic may be disclosed, such components may comprise any shape, size, style, type, model, version, class, grade, measurement, concentration, material, weight, quantity, and/or the like consistent with the intended operation of a method and/or system implementation for partial outer hard shell helmets with fiber filled plastic may be used. In places where the description above refers to particular implementations of partial outer hard shell helmets with fiber filled plastic, it should be readily apparent that a number of modifications may be made without departing from the spirit thereof and that these implementations may be applied to other helmets.

The present disclosure is to be considered as an exemplification of the principles of the disclosed methods and systems. The presently-disclosed implementations are, therefore, to be considered in all respects as illustrative, and not intended to limit the broad aspect of the disclosed concepts to the embodiments illustrated.

Many additional components and manufacturing and assembly procedures known in the art or consistent with helmet manufacture are contemplated for use with particular implementations in this disclosure. For example, although particular implementations are disclosed, such implementations and implementing components may comprise any components, models, types, materials, versions, quantities, and/or the like as is known in the art for such systems and implementing components, consistent with the intended operation.

In places where the description above refers to particular implementations of protective helmets, it should be readily apparent that a number of modifications may be made without departing from the spirit thereof. All changes that come within the meaning of and range of equivalency of the description are intended to be embraced therein.

The word “exemplary,” “example” or various forms thereof are used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” or as an “example” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Furthermore, examples are provided solely for purposes of clarity and understanding and are not meant to limit or restrict the disclosed subject matter or relevant portions of this disclosure in any manner. It is to be appreciated that a myriad of additional or alternate examples of varying scope could have been presented, but have been omitted for purposes of brevity.

Claims

1. A bicycle helmet comprising:

a helmet body comprising a plurality of spars coupled together at a front end of the helmet body and at a rear end of the helmet body, the spars separated from each other between the front end and the rear end by a plurality of channels extending from an inner surface of the helmet body to an outer surface of the helmet body, the spars formed primarily of a foamed energy management material, wherein each of the plurality of spars is separated from at least one adjacent spar of the plurality of spars by a different one of the plurality of channels having a width no greater than 30 mm, measured as a maximum channel width between two immediately adjacent spars; and wherein at least two spars of the plurality of spars are separated from each other by an enlarged channel, of the plurality of channels, the enlarged channel having a width greater than at least 60 mm, measured as a maximum channel width between two immediately adjacent spars of the plurality of spars; and

at least one shell segment formed of a fiber filled plastic and directly coupled around a majority of its border to the at least two spars separated by the enlarged channel and spanning the enlarged channel such that the enlarged channel is beneath the at least one shell segment.

2. The bicycle helmet of claim 1, wherein the at least one shell segment comprises at least two shell segments, symmetrically positioned on opposing sides of the helmet.

3. The bicycle helmet of claim 1, wherein the enlarged channel comprises a first enlarged channel and the helmet further comprising a second enlarged channel of the plurality of channels, the second enlarged channel having a width greater than at least 60 mm, measured as a maximum channel width between two immediately adjacent spars of the plurality of spars, wherein the at least one shell segment comprises first and second shell segments not connected to each other except through the energy management material, the first shell segment positioned over the first enlarged channel and the second shell segment positioned over the second enlarged channel.

4. The bicycle helmet of claim 3, wherein the first and second shell segments each comprise at least one air vent extending through the respective shell segment.

5. The bicycle helmet of claim 4, wherein each of the first and second shell segments are in-molded into the energy management material of the spars about the majority of the respective borders of the first and second shell segments.

6. The bicycle helmet of claim 1, wherein the at least one shell segment comprises at least one air vent extending through the shell segment.

7. The bicycle helmet of claim 1, wherein the energy management material is at least one of EPS and EPP.

8. The bicycle helmet of claim 1, wherein the at least one shell segment is in-molded into the energy management material of the spars about the majority of the border of the at least one shell segment.

9. The bicycle helmet of claim 1, wherein the at least one shell segment formed of the fiber filled plastic is formed of a fiber filled thermoplastic comprising fibers longer than 0.5 inches and a fiber fill between 20% and 60%.

10. A bicycle helmet comprising:

a helmet body comprising a plurality of spars separated from each other by a plurality of channels extending from an inner surface of the helmet body to an outer surface of the helmet body, the spars formed primarily of a foamed energy management material, wherein a first set of channels of the plurality of channels each comprises a channel opening sized so that a sphere having a radius of 15 mm cannot pass through the channel from outside the helmet body to inside the helmet body without contacting a side of the channel, and at least an enlarged channel of the plurality of channels comprises a channel opening sized so that the sphere having the radius of 15 mm can pass through the channel from outside of the helmet body to inside the helmet body without contacting a side of the channel; and

at least one shell formed of a fiber filled plastic and directly coupled around a majority of its border to at least two spars bordering the enlarged channel and spanning the enlarged channel such that the enlarged channel is beneath the at least one shell.

11. The bicycle helmet of claim 10, wherein the at least one shell comprises at least two shells, symmetrically positioned on opposing sides of the helmet.

12. The bicycle helmet of claim 10, wherein the enlarged channel comprises a first enlarged channel and the helmet further comprising a second enlarged channel of the plurality of channels, the second enlarged channel having a channel opening sized so that the sphere having the radius of 15 mm can pass through the channel from outside of the helmet body to inside the helmet body without contacting a side of the second enlarged channel between two immediately adjacent spars of the plurality of spars, wherein the at least one shell comprises first and second shells not connected to each other except through the energy management material, the first shell positioned over the first enlarged channel and the second shell positioned over the second enlarged channel.

13. The bicycle helmet of claim 12, wherein the first and second shells each comprise at least one air vent extending through the respective shell and each of the first and second shells are in-molded into the energy management material of the spars about a majority of respective borders of the first and second shells.

14. The bicycle helmet of claim 13, wherein the energy management material is EPS.

15. The bicycle helmet of claim 14, wherein the at least one shell formed of the fiber filled plastic is formed of a fiber filled thermoplastic comprising fibers longer than 0.5 inches and a fiber fill between 20% and 60%.

16. The bicycle helmet of claim 10, wherein the at least one shell segment comprises at least one air vent extending through the shell segment.

17. The bicycle helmet of claim 1, wherein the energy management material is at least one of EPS and EPP.

18. The bicycle helmet of claim 1, wherein the energy management material is EPS.

19. The bicycle helmet of claim 18, wherein the at least one shell formed of the fiber filled plastic is formed of a fiber filled thermoplastic comprising fibers longer than 0.5 inches and a fiber fill between 20% and 60%.