摘要：
A helmet cover (100), wherein the helmet cover comprises a unitary shell assembly (202) comprising a receiving cavity (208), an interior surface (204), and an exterior surface (206), wherein the receiving cavity is configured such that the interior surface of the unitary shell assembly is configured to contact an exterior surface of a helmet (102) and wherein the unitary shell assembly fittably and detachably covers the exterior surface of the helmet.
权利要求：
CLAIMS What is claimed is: 1. A helmet cover, wherein the helmet cover comprises a unitary shell assembly comprising a receiving cavity, an interior surface, and an exterior surface, wherein the receiving cavity is configured such that the interior surface of the unitary shell assembly is configured to contact an exterior surface of a helmet and wherein the unitary shell assembly fittably and detachably covers the exterior surface of the helmet. 2. The helmet cover of claim 1, wherein the unitary shell assembly fittably and detachably covers the exterior surface of the helmet without the use of an adjustable fastener. 3. The helmet cover of claim 1, wherein the helmet cover further comprises a finish layer, and wherein the finish layer is adhered to the exterior surface of the unitary shell assembly. 4. The helmet cover of claim 1, wherein the unitary shell assembly further comprises one or more openings therethrough and wherein the one or more openings correspond to one or more openings of the helmet. 5. The helmet cover of claim 1, wherein the unitary shell assembly further comprises a gripping member and wherein the gripping member snappably attaches to an outside edge of the exterior surface of the protective helmet. 6. The helmet cover of claim 1, wherein the unitary shell assembly is made from injection-molded thermoplastic polyurethane (TPU) or thermoformed TPU. 7. The helmet cover of claim 1, wherein the unitary shell assembly is made from a material selected from the group consisting of TPU 90, TPU95, and mixtures thereof. 8. The helmet cover of claim 1, wherein the unitary shell assembly is made from a TPU and optionally one or more additives selected from the group consisting of color pigments, finish surface chemicals, utility additives, and mixtures thereof.
9. The helmet cover of claim 1, wherein the interior surface of the unitary shell assembly comprises a plurality of microholes. 10. The helmet cover of claim 1, wherein the exterior surface of the unitary shell assembly comprises a plurality of microholes. 11. The helmet cover of claim 1, wherein the unitary shell assembly comprises a plurality of microholes, and wherein the plurality of microholes each independently have a diameter of between about 1 μm ± 0.5 μm. 12. The helmet cover of claim 1, wherein the unitary shell assembly comprises a plurality of microholes, and wherein the plurality of microholes have a distribution of approximately 3.2e7 microholes/cm2. 13. The helmet cover of claim 1, wherein the unitary shell assembly has a thickness of between 0.25 mm and 4 mm. 14. The helmet cover of claim 1, wherein the unitary shell assembly has a thickness of 1 ± 0.1 mm. 15. A method of manufacturing a helmet cover comprising: A. providing a polymeric injection unit comprising: (i) a barrel-mounted screw assembly, wherein the barrel-mounted screw assembly comprises a screw mounted within a barrel; (ii) a processing space, wherein the processing space comprises a distal end and a proximal end; and (iii) one or more nozzles in fluid communication with the processing space, wherein the one or more nozzles are located at the distal end of the processing space; B. providing an injection mold tool, wherein the injection mold tool comprises a mold cavity in fluid communication with the one or more
nozzles and wherein the injection mold tool is structured so as to form the helmet cover in a single piece; C. introducing a polymeric material into the processing space; D. melting the polymeric material within the processing space, wherein the melting is achieved by using the screw mounted within the barrel to mix the polymeric material and applying a heat source to bring the polymeric material to a first predefined temperature and to create a predefined backpressure; E. injecting a volume of the polymeric material through the one or more nozzles and into the mold cavity, wherein the volume of the polymeric material is sufficient to fill the mold cavity; F. cooling the polymeric material within the mold cavity to a second predefined temperature; and G. extracting the polymeric material within the mold cavity from the injection mold tool to provide the helmet cover. 16. The method of claim 15, wherein the polymeric material is a thermoplastic polyurethane (TPU). 17. The method of claim 15, wherein the polymeric material is selected from at least the group consisting of TPU 90, TPU95, or a mixture thereof. 18. The method of claim 15, wherein the polymeric material is TPU and optionally one or more additives selected from the group consisting of color pigments, finish surface chemicals, utility additives, and mixtures thereof. 19. The method of claim 15, wherein the helmet cover has a thickness of 1 ± 0.1 mm. 20. The method of claim 15, wherein the mold cavity is formed so as to impart microholes onto the helmet cover.
21. The method of claim 15, wherein the method of manufacturing a helmet cover further comprises imparting microholes onto the helmet cover via a mechanical process or laser drilling process after extracting the polymeric material within the mold cavity from the mold. 22. The method of claim 15, wherein the mold cavity is formed so as to impart microholes on the helmet cover and wherein the microholes have a diameter about 1 μm ± 0.5 μm. 23. The method of claim 15, wherein the first predefined temperature is 230 ± 3 °C. 24. The method of claim 15, wherein the predefined backpressure is 5 ± 1 bar. 25. The method of claim 15, wherein the second predefined temperature is 60 ± 2 °C. 26. The method of claim 15, wherein injecting the volume of the polymeric material is achieved by applying a first progressive pressure gradient and wherein the progressive pressure gradient is between about 70 bar and 15 bar. 27. The method of claim 15, wherein injecting a volume of the polymeric material occurs in 20 ± 5 seconds. 28. The method of claim 15, wherein cooling the polymeric material within the mold cavity occurs in 60 ± 5 seconds. 29. The method of claim 15, wherein the steps of introducing the polymeric material into the processing space, melting the polymeric material within the processing space, injecting a volume of the polymeric material through one or more nozzles and into the mold cavity, and cooling the polymeric material within the mold cavity occur in 130 ± 20 seconds. 30. The method of claim 15, wherein injecting the volume of the polymeric material through the one or more nozzles and into the mold cavity further comprises holding the mold cavity at a holding pressure of 100 bar when the mold cavity is 99 vol.% filled. 31. The method of claim 15 wherein providing an injection mold tool further comprises:
scanning a helmet to obtain a helmet geometry file; altering the helmet geometry file to form a helmet cover geometry file; printing a 3-dimensional helmet cover prototype; adjusting the helmet cover geometry file; and creating the injection mold tool using the helmet cover geometry file, wherein altering the helmet geometry file includes one or more of manipulating a size of the helmet cover, manipulating a shape of the helmet cover, modifying a structure of the helmet cover, adding one or more gripping members to the helmet cover, adding a plurality of microholes to the helmet cover, or a combination thereof; and wherein adjusting the helmet cover geometry file includes providing an improved fit of the helmet cover as compared to the 3-dimensional helmet cover prototype.