US20070089218A1 - Helmet Protection System - Google Patents
Helmet Protection System Download PDFInfo
- Publication number
- US20070089218A1 US20070089218A1 US11/563,804 US56380406A US2007089218A1 US 20070089218 A1 US20070089218 A1 US 20070089218A1 US 56380406 A US56380406 A US 56380406A US 2007089218 A1 US2007089218 A1 US 2007089218A1
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- United States
- Prior art keywords
- protective layer
- helmet
- canceled
- chamber
- positioning
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- A—HUMAN NECESSITIES
- A42—HEADWEAR
- A42C—MANUFACTURING OR TRIMMING HEAD COVERINGS, e.g. HATS
- A42C2/00—Manufacturing helmets by processes not otherwise provided for
- A42C2/002—In-mould forming
-
- A—HUMAN NECESSITIES
- A42—HEADWEAR
- A42B—HATS; HEAD COVERINGS
- A42B3/00—Helmets; Helmet covers ; Other protective head coverings
- A42B3/04—Parts, details or accessories of helmets
- A42B3/10—Linings
Definitions
- This invention relates generally to protective gear and more particularly to a helmet protection system.
- protective gear such as a helmet
- activities that are associated with an increased level of risk for a head injury. Examples of such activities include, but are not limited to, skiing, snowboarding, bicycling, rollerblading, rock climbing, skate boarding, and motorcycling.
- a system for protecting a device formed from polystyrene includes a body formed from polystyrene.
- the system also includes a protective layer formed from thermoplastic elastomer. The protective layer is coupled to the body during a molding process used to form the body.
- a helmet is protected by providing a protective layer over areas of a helmet body that are likely to be damaged by dropping or use of the helmet, such as a rim portion of the helmet body.
- Such protective layers may be especially advantageous for protecting the softer, “foam-like” portions of the helmet.
- FIG. 1 is a diagram illustrating one embodiment of an environment in which a helmet may be used
- FIG. 2 is a schematic diagram illustrating a perspective view of one embodiment of a protective layer that is disposed over a rim portion of the helmet shown in FIG. 1 ;
- FIG. 3 is a schematic diagram illustrating a cross-section of the helmet and the protective layer shown in FIG. 2 ;
- FIG. 4 is a flowchart illustrating one embodiment of a method for providing the protective layer for the helmet shown in FIGS. 2 and 3 .
- FIGS. 1-4 of the drawings like numerals being used for like and corresponding parts of the various drawings.
- FIG. 1 is a schematic diagram illustrating one embodiment of an environment 10 in which a helmet 20 according to one or more embodiments of the present invention may be used.
- environment 10 includes a bicyclist (user) 12 riding a bicycle 14 and wearing helmet 20 on a head 16 of user 12 .
- Helmet 20 comprises a body 50 , a front portion 24 , a rear portion 28 , a visor 30 coupled to front portion 24 , front straps 18 F, and rear straps 18 R.
- Helmet 20 is secured to head 16 through the use of front straps 18 F and rear straps 18 R, which are collectively referred to as straps 18 .
- helmet is used in this document to include any type of protective head gear, such as a bicycle helmet, a motorcycle helmet, and a hard hat.
- helmet 20 is used as an example to describe some embodiments of the present invention, any type of helmet, both protective and non-protective, may benefit from the teachings of the present invention.
- embodiments of the present invention may also be used in conjunction with products other than helmets.
- a protective head gear such as helmet 20 may reduce the severity of trauma to head 16 in case of an impact, the use of helmet 20 is strongly encouraged for many activities where the probability of injury to head 16 is relatively high.
- a body of a protective headgear such as helmet 20
- EPS expanded polystyrene
- the surface of a body formed from EPS may be easily dented, scratched or otherwise damaged, which may compromise the ability of the helmet to offer protection against impact and/or present an unattractive appearance.
- a hard plastic shell may be provided over the outer surface of the helmet body.
- portions of the existing helmet are not protected with such a shell because of certain manufacturing, cost, comfort, or other limitations.
- the bottom rim of a helmet body may be unprotected.
- a system for protecting a helmet from damage is provided by providing one or more protective layers over portions of a helmet body that are associated with a relatively high risk of damage, such as a rim portion of a helmet. This is advantageous because the level of durability of a helmet is improved while maintaining the capacity of the helmet to protect the wearer's head. Additional details of example embodiments of the invention are described below in greater detail in conjunction with FIGS. 2-4 .
- FIG. 2 is a schematic diagram illustrating a perspective view of helmet 20 that may benefit from the teachings of the present invention.
- FIG. 3 is a schematic diagram illustrating a cross-section of helmet 20 at a phantom line 60 shown in FIG. 2 .
- helmet 20 comprises a body 50 , an outer surface 36 , an inner surface 32 that defines a bowl-shaped chamber, and a rim portion 34 that is disposed between outer surface 36 and inner surface 32 at the bottom of the helmet.
- Rim portion 34 comprises a front left rim portion 34 FL, a front right rim portion 34 FR, a rear left rim portion 34 RL, and a rear right rim portion 34 RR.
- Front left rim portion 34 FL, front right rim portion 34 FR, rear left rim portion 34 RL, and rear right rim portion 34 RR may also be referred to as front left corner portion 34 FL, front right corner portion 34 FR, rear left corner portion 34 RL, and rear right corner portion 34 RR, respectively.
- helmet 20 may comprise ventilation holes, internal/external support structures, and/or other suitable components, such as a helmet retention system and a helmet fitting system.
- body 50 comprises an outer surface 24 to which a shell 54 may be coupled.
- outer surface 36 of shell 54 constitutes outer surface 36 of helmet 20 .
- outer surface 24 constitutes the outermost surface of helmet 20 .
- Body 50 may be formed from any suitable material, such as EPS.
- Rim portion 34 and inner surface 32 are parts of body 50 , and thus are formed from the same material, such as EPS.
- Shell 54 may be formed from any suitable material that is operable to resist damage and wear. An example of such a material includes, but is not limited to, polycarbonate plastic. Shell 54 may be used to add color, patterns, pictures, and/or any other suitable design to helmet 20 .
- one or more protective layers 40 may be positioned over some or all of rim portion 34 . This is advantageous in some embodiments because rim portion 34 is generally impractical to cover with shell 54 due to manufacturing, cost, comfort, or other limitations.
- Protective layer 40 may be formed from a thermoplastic elastomer (TPE) or any other suitable material. In some embodiments, protective layer 40 may be formed from a styrene-based TPE.
- protective layer 40 is advantageous in some embodiments where body 50 of helmet 20 is molded out of EPS because such protective layer 40 can be in-molded with body 50 and also adheres well to EPS.
- TPE such as styrene-based TPE
- protective layer 40 may cover certain portions (or all) of outer surface 24 of body 50 that are not covered by shell 54 .
- protective layer 40 may overlap shell 54 .
- rim portion 34 is used as an example area of body 50 that may be protected by protective layer 40
- any area of body 50 of helmet 20 where body 50 is exposed and/or that is associated with a relatively high risk of damage may be covered using protective layer 40 .
- TPE is described as one example material that may be used to form protective layer 40
- any material that is resistant to dents, scratches, and does not create comfort issues may be used to form protective layer 40 .
- protective layer 40 may be formed from a material that is softer and/or more pliable than shell 54 .
- separate pieces of protective layers 40 may be distributed to different portions of rim portion 34 .
- separate pieces of protective layers 40 are positioned at front left rim portion 34 FL, front right rim portion 34 FR, rear left rim portion 34 RL, and rear right rim portion 34 RR.
- This is advantageous in certain embodiments because helmets having different sizes can be manufactured using protective layers 40 having the same size, which simplifies the manufacturing process.
- the placement of protective layers 40 can be adjusted to accommodate the different sizes of rim portions 34 by either being positioned closer together (for smaller sizes) or farther apart (for larger sizes).
- protective layer 40 may be configured so that a portion of protective layer 40 extends further outwardly from body 50 than does shell 54 , as indicated by an arrow 70 . This is advantageous in some embodiments because the clam shell used to mold helmet 20 may bear down on the protruding portion of protective layer 40 , indicated by arrow 70 , to maintain the position of protective layer 40 during the molding process.
- FIG. 4 is a flowchart illustrating one embodiment of a method 100 for providing protective layer 40 for helmet 20 shown in FIGS. 2 and 3 .
- Method 100 starts at step 104 .
- a clam shell mold having a male side and a female side each defining a portion of a chamber that has a shape of helmet 20 is provided.
- shell 54 is positioned in one side of the mold (typically the female side, although this is not required) in a manner well known to one skilled in the art.
- a suitable material such as polycarbonate plastic, may be used to form shell 54 .
- Step 110 may be omitted in some embodiments.
- protective layer 40 is positioned in desired locations of the mold.
- protective layer 40 is positioned in a male side of the clam shell mold; however, in some embodiments, protective layer 40 may be positioned in a female side of the clam shell mold.
- step 112 may be performed before step 110 or in conjunction with step 110 .
- a suitable material for forming body 50 of helmet 20 such as EPS, may be provided into the mold.
- EPS may be pressure-filled into the chamber.
- EPS in the chamber of the mold is heated to form body 50 of helmet 20 , thus in-molding protective layer 40 with body 50 of helmet 20 .
- EPS may be heated in any suitable method.
- EPS may be exposed to steam.
- heating step 118 may be performed while performing step 114 .
- Method 100 stops at step 120 .
- a helmet such as helmet 20
- any device that is molded out of a shock-absorbing and/or insulation material, such as EPS, that is relatively easily damaged may benefit from the teachings of the present invention.
- EPS shock-absorbing and/or insulation material
- a portable cooler and a beverage holder formed from EPS may benefit from the use of a protective layer to protect against surface and body damage.
Abstract
According to some embodiments of the invention, a system for protecting a device formed from polystyrene is provided. The system includes a body formed from polystyrene. The system also includes a protective layer formed from thermoplastic elastomer. The protective layer is coupled to the body during a molding process used to form the body.
Description
- This invention relates generally to protective gear and more particularly to a helmet protection system.
- A physical impact to the head of a person may cause serious injury or death. To reduce the probability of such consequences, protective gear, such as a helmet, is often used in activities that are associated with an increased level of risk for a head injury. Examples of such activities include, but are not limited to, skiing, snowboarding, bicycling, rollerblading, rock climbing, skate boarding, and motorcycling.
- According to some embodiments of the invention, a system for protecting a device formed from polystyrene is provided. The system includes a body formed from polystyrene. The system also includes a protective layer formed from thermoplastic elastomer. The protective layer is coupled to the body during a molding process used to form the body.
- Some embodiments of the invention provide numerous technical advantages. Other embodiments may realize some, none, or all of these advantages. For example, according to one embodiment, a helmet is protected by providing a protective layer over areas of a helmet body that are likely to be damaged by dropping or use of the helmet, such as a rim portion of the helmet body. Such protective layers may be especially advantageous for protecting the softer, “foam-like” portions of the helmet.
- Other advantages may be readily ascertainable by those skilled in the art.
- Reference is now made to the following description taken in conjunction with the accompanying drawings, wherein like reference numbers represent like parts, in which:
-
FIG. 1 is a diagram illustrating one embodiment of an environment in which a helmet may be used; -
FIG. 2 is a schematic diagram illustrating a perspective view of one embodiment of a protective layer that is disposed over a rim portion of the helmet shown inFIG. 1 ; -
FIG. 3 is a schematic diagram illustrating a cross-section of the helmet and the protective layer shown inFIG. 2 ; and -
FIG. 4 is a flowchart illustrating one embodiment of a method for providing the protective layer for the helmet shown inFIGS. 2 and 3 . - Embodiments of the invention are best understood by referring to
FIGS. 1-4 of the drawings, like numerals being used for like and corresponding parts of the various drawings. -
FIG. 1 is a schematic diagram illustrating one embodiment of anenvironment 10 in which ahelmet 20 according to one or more embodiments of the present invention may be used. As shown inFIG. 1 ,environment 10 includes a bicyclist (user) 12 riding abicycle 14 and wearinghelmet 20 on ahead 16 ofuser 12.Helmet 20 comprises abody 50, afront portion 24, arear portion 28, avisor 30 coupled tofront portion 24,front straps 18F, andrear straps 18R.Helmet 20 is secured tohead 16 through the use offront straps 18F andrear straps 18R, which are collectively referred to as straps 18. The term “helmet” is used in this document to include any type of protective head gear, such as a bicycle helmet, a motorcycle helmet, and a hard hat. Althoughhelmet 20 is used as an example to describe some embodiments of the present invention, any type of helmet, both protective and non-protective, may benefit from the teachings of the present invention. Furthermore, as described below, embodiments of the present invention may also be used in conjunction with products other than helmets. - Referring again to
FIG. 1 , ifuser 12 were to accidentally fall off ofbicycle 14,user 12 may suffer various injuries, including an impact tohead 16. Because the use of a protective head gear such ashelmet 20 may reduce the severity of trauma to head 16 in case of an impact, the use ofhelmet 20 is strongly encouraged for many activities where the probability of injury tohead 16 is relatively high. - A body of a protective headgear, such as
helmet 20, is generally formed from a shock-absorbing material, such as expanded polystyrene (EPS). The surface of a body formed from EPS may be easily dented, scratched or otherwise damaged, which may compromise the ability of the helmet to offer protection against impact and/or present an unattractive appearance. To protect against such a damage, a hard plastic shell may be provided over the outer surface of the helmet body. However, portions of the existing helmet are not protected with such a shell because of certain manufacturing, cost, comfort, or other limitations. For example, the bottom rim of a helmet body may be unprotected. - According to some embodiments of the present invention, a system for protecting a helmet from damage is provided by providing one or more protective layers over portions of a helmet body that are associated with a relatively high risk of damage, such as a rim portion of a helmet. This is advantageous because the level of durability of a helmet is improved while maintaining the capacity of the helmet to protect the wearer's head. Additional details of example embodiments of the invention are described below in greater detail in conjunction with
FIGS. 2-4 . -
FIG. 2 is a schematic diagram illustrating a perspective view ofhelmet 20 that may benefit from the teachings of the present invention.FIG. 3 is a schematic diagram illustrating a cross-section ofhelmet 20 at aphantom line 60 shown inFIG. 2 . Referring toFIG. 2 ,helmet 20 comprises abody 50, anouter surface 36, aninner surface 32 that defines a bowl-shaped chamber, and arim portion 34 that is disposed betweenouter surface 36 andinner surface 32 at the bottom of the helmet.Rim portion 34 comprises a front left rim portion 34FL, a front right rim portion 34FR, a rear left rim portion 34RL, and a rear right rim portion 34RR. Front left rim portion 34FL, front right rim portion 34FR, rear left rim portion 34RL, and rear right rim portion 34RR may also be referred to as front left corner portion 34FL, front right corner portion 34FR, rear left corner portion 34RL, and rear right corner portion 34RR, respectively. In certain embodiments, although not explicitly shown inFIG. 2 ,helmet 20 may comprise ventilation holes, internal/external support structures, and/or other suitable components, such as a helmet retention system and a helmet fitting system. - Referring to and as shown in
FIG. 3 ,body 50 comprises anouter surface 24 to which ashell 54 may be coupled. Thus, in certain embodiments,outer surface 36 ofshell 54 constitutesouter surface 36 ofhelmet 20. However, whereshell 54 is omitted fromhelmet 20,outer surface 24 constitutes the outermost surface ofhelmet 20.Body 50 may be formed from any suitable material, such as EPS.Rim portion 34 andinner surface 32 are parts ofbody 50, and thus are formed from the same material, such as EPS. Shell 54 may be formed from any suitable material that is operable to resist damage and wear. An example of such a material includes, but is not limited to, polycarbonate plastic. Shell 54 may be used to add color, patterns, pictures, and/or any other suitable design tohelmet 20. - Referring to
FIGS. 2 and 3 , according to certain embodiments of the invention, one or moreprotective layers 40 may be positioned over some or all ofrim portion 34. This is advantageous in some embodiments becauserim portion 34 is generally impractical to cover withshell 54 due to manufacturing, cost, comfort, or other limitations.Protective layer 40 may be formed from a thermoplastic elastomer (TPE) or any other suitable material. In some embodiments,protective layer 40 may be formed from a styrene-based TPE. Using certain types of TPE, such as styrene-based TPE, to formprotective layer 40 is advantageous in some embodiments wherebody 50 ofhelmet 20 is molded out of EPS because suchprotective layer 40 can be in-molded withbody 50 and also adheres well to EPS. However, embodiments using other types of TPE, including olefin-based TPE, are also envisioned. In certain embodiments,protective layer 40 may cover certain portions (or all) ofouter surface 24 ofbody 50 that are not covered byshell 54. In certain embodiments,protective layer 40 may overlapshell 54. Althoughrim portion 34 is used as an example area ofbody 50 that may be protected byprotective layer 40, any area ofbody 50 ofhelmet 20 wherebody 50 is exposed and/or that is associated with a relatively high risk of damage may be covered usingprotective layer 40. Although TPE is described as one example material that may be used to formprotective layer 40, any material that is resistant to dents, scratches, and does not create comfort issues may be used to formprotective layer 40. In some embodiments,protective layer 40 may be formed from a material that is softer and/or more pliable thanshell 54. - In certain embodiments, separate pieces of
protective layers 40 may be distributed to different portions ofrim portion 34. For example, as shown inFIG. 2 , separate pieces ofprotective layers 40 are positioned at front left rim portion 34FL, front right rim portion 34FR, rear left rim portion 34RL, and rear right rim portion 34RR. This is advantageous in certain embodiments because helmets having different sizes can be manufactured usingprotective layers 40 having the same size, which simplifies the manufacturing process. For example, regardless of the size ofhelmet 20, the placement ofprotective layers 40 can be adjusted to accommodate the different sizes ofrim portions 34 by either being positioned closer together (for smaller sizes) or farther apart (for larger sizes). - Referring to
FIG. 3 , in certain embodiments,protective layer 40 may be configured so that a portion ofprotective layer 40 extends further outwardly frombody 50 than does shell 54, as indicated by anarrow 70. This is advantageous in some embodiments because the clam shell used to moldhelmet 20 may bear down on the protruding portion ofprotective layer 40, indicated byarrow 70, to maintain the position ofprotective layer 40 during the molding process. -
FIG. 4 is a flowchart illustrating one embodiment of amethod 100 for providingprotective layer 40 forhelmet 20 shown inFIGS. 2 and 3 .Method 100 starts atstep 104. Atstep 108, a clam shell mold having a male side and a female side each defining a portion of a chamber that has a shape ofhelmet 20 is provided. Atstep 110,shell 54 is positioned in one side of the mold (typically the female side, although this is not required) in a manner well known to one skilled in the art. A suitable material, such as polycarbonate plastic, may be used to formshell 54. Step 110 may be omitted in some embodiments. Atstep 112,protective layer 40 is positioned in desired locations of the mold. For example,protective layer 40 is positioned in a male side of the clam shell mold; however, in some embodiments,protective layer 40 may be positioned in a female side of the clam shell mold. In certain embodiments,step 112 may be performed beforestep 110 or in conjunction withstep 110. Atstep 114, a suitable material for formingbody 50 ofhelmet 20, such as EPS, may be provided into the mold. For example, negative pressure may be created in the chamber defined by the mold and EPS may be pressure-filled into the chamber. Atstep 118, EPS in the chamber of the mold is heated to formbody 50 ofhelmet 20, thus in-moldingprotective layer 40 withbody 50 ofhelmet 20. EPS may be heated in any suitable method. For example, EPS may be exposed to steam. In certain embodiments,heating step 118 may be performed while performingstep 114.Method 100 stops atstep 120. - Although a helmet, such as
helmet 20, is used as an example device that may benefit from the teachings of the present invention, any device that is molded out of a shock-absorbing and/or insulation material, such as EPS, that is relatively easily damaged may benefit from the teachings of the present invention. For example, a portable cooler and a beverage holder formed from EPS may benefit from the use of a protective layer to protect against surface and body damage. - Although some embodiments of the present invention have been described in detail, it should be understood that various changes, substitutions, and alterations can be made hereto without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (17)
1. (canceled)
2. (canceled)
3. (canceled)
4. (canceled)
5. (canceled)
6. (canceled)
7. (canceled)
8. (canceled)
9. (canceled)
10. (canceled)
11. A method for providing a protective layer, comprising:
providing a clam shell mold defining a chamber;
positioning a protective layer of thermoplastic elastomer in the chamber;
after positioning the protective layer, providing expanded polystyrene in the chamber; and
heating the expanded polystyrene in the chamber.
12. The method of claim 11 , wherein the chamber comprises a shape of a helmet.
13. The method of claim 11 , wherein heating the expanded polystyrene comprises exposing the expanded polystyrene to steam.
14. The method of claim 11 , wherein providing expanded polystyrene comprises providing expanded polystyrene so that the protective layer is disposed on an outer surface of the expanded polystyrene after the method is complete.
15. The method of claim 11 , wherein the chamber comprises a shape of a helmet having an outer surface, an inner surface, and a rim portion disposed between the outer surface and the inner surface, and positioning the protective layer comprises positioning the protective layer at a portion of the chamber that has a shape of the rim portion.
16. The method of claim 11 , wherein the protective layer is a first protective layer, and further comprising positioning a second protective layer of plastic shell in the chamber before providing the expanded polystyrene.
17. The method of claim 11 , wherein the clam shell mold comprises a first side and a second side, positioning a protective layer comprises positioning the first protective layer in the first side, and positioning a second protective layer comprises positioning the second protective layer of plastic shell in the second side of the clam shell mold.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US11/563,804 US20070089218A1 (en) | 2004-08-03 | 2006-11-28 | Helmet Protection System |
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US10/911,243 US7140049B2 (en) | 2004-08-03 | 2004-08-03 | Helmet protection system |
US11/563,804 US20070089218A1 (en) | 2004-08-03 | 2006-11-28 | Helmet Protection System |
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US10/911,243 Division US7140049B2 (en) | 2004-08-03 | 2004-08-03 | Helmet protection system |
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US20070089218A1 true US20070089218A1 (en) | 2007-04-26 |
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-
2004
- 2004-08-03 US US10/911,243 patent/US7140049B2/en active Active
-
2006
- 2006-11-28 US US11/563,804 patent/US20070089218A1/en not_active Abandoned
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US20020114859A1 (en) * | 1999-05-07 | 2002-08-22 | Future Foam Technology, Llc | Mold assembly for making an expanded polystyrene article |
US6401258B1 (en) * | 1999-11-04 | 2002-06-11 | Corey Wilson | Headgear for sports fans |
US20040143879A1 (en) * | 2001-02-02 | 2004-07-29 | Scott Robertson | Eye gear helmet fastener |
US20030140401A1 (en) * | 2002-01-25 | 2003-07-31 | Tun-Jen Ku | Impact resistant structure of safety helmet |
US20040139531A1 (en) * | 2002-12-06 | 2004-07-22 | Moore Dan T. | Custom fitted helmet and method of making the same |
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US20060026742A1 (en) * | 2004-08-03 | 2006-02-09 | Arne Lang-Ree | Helmet protection system |
Also Published As
Publication number | Publication date |
---|---|
US20060026742A1 (en) | 2006-02-09 |
US7140049B2 (en) | 2006-11-28 |
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Legal Events
Date | Code | Title | Description |
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AS | Assignment |
Owner name: BELL SPORTS, INC., TEXAS Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:LANG-REE, ARNE;MULLER, HILGARD N.;REEL/FRAME:018556/0467 Effective date: 20040802 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |