U.S. patent application number 14/175788 was filed with the patent office on 2014-08-14 for helmet with custom foam liner and removable / replaceable layers of crushable energy absorption material.
The applicant listed for this patent is Blake Henderson. Invention is credited to Blake Henderson.
Application Number | 20140223641 14/175788 |
Document ID | / |
Family ID | 51296354 |
Filed Date | 2014-08-14 |
United States Patent
Application |
20140223641 |
Kind Code |
A1 |
Henderson; Blake |
August 14, 2014 |
HELMET WITH CUSTOM FOAM LINER AND REMOVABLE / REPLACEABLE LAYERS OF
CRUSHABLE ENERGY ABSORPTION MATERIAL
Abstract
Multi-layered helmets deformably absorb an impact to a wearer
that are provided with a rigid outer shell, a plurality of
collapsible members configured to be permanently deformable to
absorb energy in response to an applied force, and a flexible inner
liner. The collapsible members are individually attachable to and
removable from the inner surface of the rigid outer shell and to
the flexible inner liner in a manner allowing individual
replacement of a collapsible member upon being permanently
deformed. The inside of the flexible inner liner is configured to
face the head of a wearer.
Inventors: |
Henderson; Blake; (Park
City, UT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Henderson; Blake |
Park City |
UT |
US |
|
|
Family ID: |
51296354 |
Appl. No.: |
14/175788 |
Filed: |
February 7, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61762939 |
Feb 10, 2013 |
|
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Current U.S.
Class: |
2/411 |
Current CPC
Class: |
A42B 3/127 20130101;
A42B 3/065 20130101 |
Class at
Publication: |
2/411 |
International
Class: |
A42B 3/32 20060101
A42B003/32 |
Claims
1. A multi-layered helmet for deformably absorbing an impact to a
wearer, the multi-layered helmet comprising: a rigid outer shell
having an inner surface; a plurality of collapsible members, the
collapsible members permanently deformable in response to an
applied force, the deformation absorbing impact energy from the
applied force, the plurality of collapsible members being
individually attachable to and removable from the inner surface of
the rigid outer shell, wherein the plurality of collapsible members
are individually replaceable upon being permanently deformed; a
flexible inner liner having an outer surface and an inner surface,
the plurality of collapsible members being individually attachable
to and removable from the outer surface of the flexible inner
liner, the inner surface of the flexible inner liner being
configured to rest against the heard of a wearer.
2. The multi-layered helmet of claim 1, further comprising: a
plurality of voids formed at least in part by spaces between the
plurality of collapsible members; wherein the flexible inner liner
comprises extension portions extending toward the rigid outer shell
and fitting within the plurality of voids.
3. The multi-layered helmet of claim 1, wherein the permanent
deformation of at least one of the plurality of collapsible members
is a breakage or a snapping of the least one of the plurality of
collapsible members.
4. The multi-layered helmet of claim 1, wherein at least one of the
plurality of collapsible members is permanently deformed by a
crushing or a folding of the at least one of the plurality of
collapsible members.
5. The multi-layered helmet of claim 1, wherein the plurality of
collapsible members are removably attachable to the rigid outer
shell and the flexible inner liner by hook and loop fasteners
covering at least a portion of the inner surface of the rigid outer
shell, the plurality of collapsible members, and the outer surface
of the flexible inner liner.
6. The multi-layered helmet of claim 5, wherein a first portion of
the hook and loop fasteners removably attaches at least one of the
plurality of collapsible members to the rigid outer shell and a
second portion of the hook and loop fasteners removably attaches
the at least one of the plurality of collapsible members to the
flexible inner liner, the first and second portions having
different attachment strengths.
7. The multi-layered helmet of claim 1, wherein the plurality of
collapsible members are removably attachable to the rigid outer
shell and the flexible inner liner by a plurality of snap-fit
connectors extending between the rigid outer shell, the plurality
of collapsible members, and/or the flexible inner liner.
8. The multi-layered helmet of claim 7, wherein the plurality of
snap-fit connectors are pins having a shear breakage section
configured to break in response to an applied shear force, the
shear breakage section being positioned to be subjected to an
applied shear force when the plurality of collapsible members
translate relative to the rigid outer shell or the flexible inner
liner.
9. The multi-layered helmet of claim 8, wherein the plurality of
snap-fit connectors are removably insertable into openings in the
plurality of collapsible members.
10. The multi-layered helmet of claim 1, wherein the plurality of
collapsible members are removably attachable to the rigid outer
shell and the flexible inner liner by a releasable ridge-and-groove
connector.
11. The multi-layered helmet of claim 1, wherein the flexible inner
liner has varying thickness when measured relative to the inner
surface of the rigid outer shell.
12. The multi-layered helmet of claim 1, wherein a first portion of
the plurality of collapsible members has a different rigidity than
a second portion of the plurality of collapsible members.
13. The multi-layered helmet of claim 1, wherein the plurality of
collapsible members collapse to permit rotational or translational
movement of the flexible inner liner relative to the rigid outer
shell.
14. The multi-layered helmet of claim 1, wherein the plurality of
collapsible members collapse to permit rotational or translational
movement of the outer shell relative to the flexible inner
liner.
15. The multi-layered helmet of claim 1, further comprising a chin
strap configured to secure the helmet to a head of the wearer.
16. A method of manufacturing a multi-layered helmet for deformably
absorbing an impact to a head of a wearer, the method comprising:
providing a rigid outer shell having an inner surface; attaching a
plurality of collapsible members to the inner surface of the rigid
outer shell, the plurality of collapsible members being permanently
deformable to absorb impact energy in response to a force applied
to the rigid outer shell, the plurality of collapsible members
having inner surfaces; attaching a flexible inner liner to the
inner surfaces of the plurality of collapsible members.
17. The method of claim 16, wherein attaching the plurality of
collapsible members and attaching the flexible inner liner
comprises removably attaching the plurality of collapsible members
and removably attaching the flexible inner liner, respectively.
18. The method of claim 16, wherein removably attaching the
plurality of collapsible members further comprises: providing a
plurality of pin inserts; forming a plurality of cavities in the
plurality of collapsible members, the plurality of cavities being
shaped to receive the pin inserts; inserting the plurality of pin
inserts into the plurality of cavities and into the rigid outer
shell and flexible inner liner, the pin inserts removably attaching
the plurality of collapsible members to the rigid outer shell and
to the flexible inner liner.
19. The method of claim 16, wherein the plurality of collapsible
members are more securely removably attached to the rigid outer
shell than to the flexible inner liner.
20. The method of claim 16, further comprising: shaping the
flexible inner liner to conform to the inner surfaces of the
plurality of collapsible members and to a surface of the head of
the wearer, the flexible inner liner including expansion portions
to fill a plurality of voids between the plurality of collapsible
members and the head of the wearer.
21. The method of claim 16, wherein the flexible inner liner is
shaped by molding the flexible inner liner to a shape of the inner
surfaces of the plurality of collapsible members or rigid outer
surface.
22. The method of claim 16, wherein a first portion and a second
portion of the plurality of collapsible members is attached to the
inner surface of the outer shell, and the first portion has greater
rigidity than the second portion of the plurality of collapsible
members.
23. The method of claim 16, wherein upon permanent deformation of
at least one of the plurality of collapsible members, the method
further comprises: detaching the flexible inner liner from the
inner surfaces of the plurality of collapsible members; detaching a
consumed first collapsible member from the inner surface of the
rigid outer shell, wherein the consumed first collapsible member is
individually detachable relative to the plurality of collapsible
members; replacing the consumed first collapsible member with a
second collapsible member, the second collapsible member having
equivalent shape to the consumed first collapsible member;
reattaching the flexible inner liner to the inner surfaces of the
plurality of collapsible members.
24. A method of manufacturing a custom multi-layered helmet, the
method comprising: providing a rigid outer shell having an inner
surface, the inner surface of the rigid outer shell being attached
to a rigid collapsible pad having an inner surface; positioning a
moldable liner blank adjacent to the inner surface of the rigid
collapsible pad and adjacent to a surface of a head of a wearer,
the liner blank contacting the inner surface of the rigid
collapsible pad and the surface of the head simultaneously; molding
the liner blank to a shape defined by the inner surface of the
rigid collapsible pad and the surface of the head; stiffening the
liner blank to retain the shape; removably attaching the liner
blank to the rigid outer shell or rigid collapsible pad.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of priority from U.S.
Provisional Application No. 61/762,939, filed Feb. 10, 2013, and
entitled HELMET WITH CUSTOM FOAM LINER AND REMOVABLE LAYER OF
CRUSHABLE ENERGY ABSORPTION MATERIAL, the disclosure of which is
incorporated, in its entirety, by this reference.
TECHNICAL FIELD
[0002] The following relates generally to protective helmets and
specifically to customized protective helmets having replaceable
collapsible parts.
BACKGROUND
[0003] Protective helmets are used in a wide range of industrial,
military, and recreational activities, including construction,
vehicle safety, sports, motorcycling, and other applications.
Traditionally, these helmets provide a protective barrier against
the application of forces to the head that are likely to cause head
injuries or concussion of the brain. This is done by a
substantially rigid foam layer positioned to portions of the
wearer's head that are prone to being impacted. This foam layer is
strapped to the head, usually by chin straps. Under normal use, the
foam layer is designed to rigidly maintain its shape, but when the
helmet is impacted by a great enough force, the rigid foam crushes
or collapses and absorbs at least a portion of the energy, thereby
reducing the overall impulse absorbed by the wearer.
[0004] In some cases, the foam layer is externally covered by a
rigid plastic, composite, or other durable material. This outer
layer may be stiff enough to prevent the foam from incidental
damage occurring from normal use while still being flexible enough
to deform into the foam layer upon a serious impact. The foam layer
may also include inner pads positioned between the foam layer and
the user's head to improve comfort and to absorb minor movements of
the helmet relative to the wearer.
[0005] Existing helmet technology does not generally provide enough
energy absorption for the wearer's head. A rigid shell on the outer
area of the helmet is typically designed to maintain its integrity
even under very high impacts, and therefore the helmet as a whole
does not absorb enough energy to protect the wearer. The inner foam
protection is also designed in the same way. It is designed to keep
its integrity on softer and medium impact Forces. This does not
allow for as much energy absorption because the material just
doesn't crush or collapse to the extent of the proposed foam
protection layers. This is usually done to protect the helmet and
allow it to be reusable, since failure of the shell or the foam
layer within the shell is catastrophic, unrepairable damage to the
helmet.
[0006] Generally speaking, these protective helmets are only
designed to sustain one major impact. When the foam layer
collapses, it breaks and loses a significant amount of its ability
to absorb energy a second time, and the entire helmet must be
discarded. This leads to excessive waste and can be unduly costly
to replace, particularly when a helmet is cosmetically or
functionally customized. Other helmets may be able to withstand
repeated impacts, but the materials used in their construction are
expensive and, in some cases, less effective in a crash.
[0007] Additionally, protective helmets are often found in a number
of discrete sizes that are supposed to fit a general cross-section
of the public. While a specific helmet may technically be wearable,
too frequently it may allow an undesirable amount of relative
movement between the head and the inner surfaces of the helmet.
Some helmets provide soft cushioning that forms to each wearer's
head, but this may reduce safety due to loosening the fit of the
helmet, and may lead to the helmets feeling tighter or looser than
is comfortable for some wearers.
[0008] Therefore, improvements in protective helmets are
desirable.
SUMMARY
[0009] According to at least one embodiment, a multi-layered helmet
for deformably absorbing an impact to a wearer may be disclosed and
provided herein. The multi-layered helmet may comprise a rigid
outer shell having an inner surface, a plurality of collapsible
members individually attachable to and removable from the inner
surface of the rigid outer shell, wherein the plurality of
collapsible members are individually replaceable upon being
permanently deformed, and a flexible inner liner having an outer
surface and an inner surface, the plurality of collapsible members
being individually attachable to and removable from the outer
surface of the inner liner, the inner surface of the flexible inner
liner being configured to rest against the head of a wearer. The
plurality of collapsible members may be permanently deformable in
response to an applied force, wherein the deformation absorbs
impact energy from the applied force. The multi-layered helmet may
also include a chin strap configured to secure the helmet to the
head of the wearer.
[0010] The helmet may also comprise a plurality of voids formed at
least in part by spaces between the plurality of collapsible
members, wherein the flexible inner liner comprises extension
portions extending toward the rigid outer shell and fitting within
the plurality of voids. The permanent deformation of at least one
of the plurality of collapsible members may be a breakage or a
snapping of the least one of the plurality of collapsible members.
At least one of the plurality of collapsible members may be
permanently deformed by a crushing or a folding of the at least one
of the plurality of collapsible members.
[0011] The plurality of collapsible members may be removably
attachable to the rigid outer shell and the flexible inner liner by
hook and loop fasteners covering at least a portion of the inner
surface of the rigid outer shell, the plurality of collapsible
members, and the outer surface of the flexible inner liner. A first
portion of the hook and loop fasteners may removably attach at
least one of the plurality of collapsible members to the rigid
outer shell and a second portion of the hook and loop fasteners may
removably attach the at least one of the plurality of collapsible
members to the flexible inner liner, wherein the first and second
portions may have different attachment strengths.
[0012] The plurality of collapsible members of the helmet may be
removably attachable to the rigid outer shell and the flexible
inner liner by a plurality of snap-fit connectors extending between
the rigid outer shell, the collapsible members, and/or the flexible
inner liner. These snap-fit connectors may be pins having a shear
breakage section configured to break in response to an applied
shear force. The shear breakage section may be positioned to be
subjected to an applied shear force when the collapsible members
translate relative to the rigid outer shell or the flexible inner
liner. The snap-fit connectors may be removably insertable into
openings in the plurality of collapsible members.
[0013] The plurality of collapsible members may also be removably
attachable to the rigid outer shell and the flexible inner liner by
a releasable ridge-and-groove connector.
[0014] The flexible inner liner may have varying thickness when
measured relative to the inner surface of the rigid outer
shell.
[0015] A first portion of the plurality of collapsible members may
have a different rigidity than a second portion of the plurality of
collapsible members.
[0016] The collapsible members may collapse to permit rotational or
translational movement of the flexible inner liner relative to the
rigid outer shell. Similarly, the collapsible members may collapse
to permit rotational or translational movement of the outer shell
relative to the flexible inner liner.
[0017] In another aspect of the present disclosure, a method of
manufacturing a multi-layered helmet for deformably absorbing an
impact to a head of a wearer is provided. The method may include
providing a rigid outer shell having an inner surface, attaching a
plurality of collapsible members to the inner surface of the rigid
outer shell, the collapsible members being permanently deformable
to absorb impact energy in response to a force applied to the rigid
outer shell and having inner surfaces, and attaching a flexible
inner liner to the inner surfaces of the plurality of collapsible
members.
[0018] Attaching the plurality of collapsible members and attaching
the flexible liner may comprise removably attaching the plurality
of collapsible members and removably attaching the flexible inner
liner, respectively. Removably attaching the plurality of
collapsible members may further comprise providing a plurality of
pin inserts, forming a plurality of cavities in the plurality of
collapsible members, the plurality of cavities being shaped to
receive the pin inserts, and inserting the plurality of pin inserts
into the plurality of cavities and into the rigid outer shell and
flexible inner liner, the pin inserts removably attaching the
plurality of collapsible members to the rigid outer shell and to
the flexible inner liner. The plurality of collapsible members may
be more securely removably attached to the rigid outer shell than
to the flexible inner liner.
[0019] In another embodiment, the method may include shaping the
flexible inner liner to conform to the inner surfaces of the
plurality of collapsible members and to a surface of the head of
the wearer, wherein the flexible inner liner may include expansion
portions to fill a plurality of voids between the plurality of
collapsible members and the head of the wearer. The flexible inner
liner may be shaped by molding the flexible inner liner to the
shape of the inner surfaces of the collapsible members or rigid
outer surface. The flexible inner liner may also comprise
compartments or cavities that will allow for containing or contain
a liquid or semi-liquid foam material. This material may be
chemically activated to allow a custom forming and fit. This
configuration may provide a better custom fit to the contours of a
wearer's head.
[0020] A first portion and a second portion of the plurality of
collapsible members may be attached to the inner surface of the
outer shell, and the first portion may have greater rigidity than
the second portion of the plurality of collapsible members.
[0021] Upon permanent deformation of at least one of the plurality
of collapsible members, the method may further comprise detaching
the flexible inner liner from the inner surfaces of the plurality
of collapsible members, detaching a consumed first collapsible
member from the inner surface of the rigid outer shell, wherein the
consumed first collapsible member is individually detachable
relative to the plurality of collapsible members, replacing the
consumed first collapsible member with a second collapsible member,
the second collapsible member having equivalent shape to the
consumed first collapsible member, and reattaching the flexible
inner liner to the inner surfaces of the plurality of collapsible
members.
[0022] In another aspect of the present disclosure, a method of
manufacturing a custom multi-layered helmet may comprise providing
a rigid outer shell having an inner surface, the inner surface of
the rigid outer shell being attached to a rigid collapsible pad
having an inner surface, positioning a moldable liner blank
adjacent to the inner surface of the rigid collapsible pad and
adjacent to a surface of a head of a wearer, the liner blank
contacting the inner surface of the rigid collapsible pad and the
surface of the head simultaneously, molding the liner blank to a
shape defined by the inner surface of the rigid collapsible pad and
the surface of the head, stiffening the liner blank to retain the
shape, and removably attaching the liner blank to the rigid outer
shell or rigid collapsible pad. The molding process may be
implemented using a capsule that is positioned around the head of
the wearer and then inserting moldable material between the
surfaces of the head and the surfaces of the collapsible pad
members. The capsule may act as the outer shell of the helmet for
the customization process. It may provide a boundary for the foam
to push against, allowing the right amount of pressure to form to
the head and also fill in to fit in the normal shell of the
helmet.
[0023] The foregoing and other features, utilities and advantages
of the invention will be apparent from the following more
particular description of a preferred embodiment of the invention
as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The accompanying drawings and figures illustrate a number of
exemplary embodiments and are part of the specification. Together
with the present description, these drawings demonstrate and
explain various principles of this disclosure. A further
understanding of the nature and advantages of the present invention
may be realized by reference to the following drawings. In the
appended figures, similar components or features may have the same
reference label.
[0025] FIG. 1 is a perspective view of a helmet according to an
exemplary embodiment of the present disclosure.
[0026] FIG. 2 is a bottom view of the helmet of FIG. 1.
[0027] FIG. 3 is a side section view of a helmet according to
another exemplary embodiment of the present disclosure.
[0028] FIG. 4 is an exploded side section view of the helmet of
FIG. 3.
[0029] FIG. 5 is an illustration of a side section view of the
helmet of FIG. 3 prior to final formation of a flexible inner
layer.
[0030] FIG. 6 is a partial side section view illustration of one
way multiple layers of a helmet may be attached to each other.
[0031] FIG. 7 is another partial side section view illustration of
a way multiple layers of a helmet may be attached to each
other.
[0032] FIG. 8 is another partial side section view illustration of
a way multiple layers of a helmet may be attached to each
other.
[0033] FIG. 9A shows a collapsible pad member attachable using tabs
and pockets in an unsecured position.
[0034] FIG. 9B shows the collapsible pad member of FIG. 9A in a
secured position.
[0035] FIGS. 10A-10K show cross-sectional exemplary profiles of
collapsible pad members.
[0036] FIG. 11 shows a perspective view of an exemplary collapsible
pad member profile.
[0037] FIGS. 12A-12M show photographs of exemplary test members for
the profile shapes of FIGS. 10A-10K and 11.
[0038] FIGS. 13A-13B show another embodiment of a collapsible
member configured to be attachable to an outer shell of a helmet of
another embodiment of the present disclosure.
[0039] FIG. 14 illustrates another embodiment of a second impact
layer of FIG. 13.
[0040] FIG. 15 illustrates another embodiment of a second impact
layer of FIG. 13.
[0041] While the embodiments described herein are susceptible to
various modifications and alternative forms, specific embodiments
have been shown by way of example in the drawings and will be
described in detail herein. However, the exemplary embodiments
described herein are not intended to be limited to the particular
forms disclosed. Rather, the instant disclosure covers all
modifications, equivalents, and alternatives falling within the
scope of the appended claims.
DETAILED DESCRIPTION
[0042] In some aspects of the present disclosure, multi-layered
helmets are described. Such helmets may include a rigid outer shell
within which a plurality of collapsible pad members is attached.
The collapsible pad members may be substantially rigid in order to
absorb energy from a strong impulse applied to the outer shell. The
collapsible pad members may be individually separate or separable
from each other and may also be removable from the outer shell.
This may allow the helmet to customize the flexibility and energy
absorption characteristics of different regions within the helmet
based on the types of pad members placed in each section of the
helmet.
[0043] The function of the layers may be considered analogous to
safety features used in competitive car racing (e.g., NASCAR), but
instead of protecting a driver of a vehicle, the wearer of a helmet
is protected from absorbing direct impacts and rotational impact
energy. In competitive racing, the race tracks have a safety wall,
the competitors' vehicles have specially-designed chassis, and the
drivers use a custom-fitted seat and head harness system. The
safety wall crushes or collapses on impact, then the car frame
crushes, and the custom-fitted seat and harness keeps the driver
stable and act as a final layer of protection as the wall and
chassis absorb most of the impact energy.
[0044] In this analogy, the rigid outer shell of the helmet may be
compared to the safety wall, the collapsible pad members may be
likened to the chassis of the racing vehicle, and the flexible
inner liner may be compared to the seat and harness in the vehicle.
Thus, the outer shell of the helmet may be first to receive an
impact in a collision with the helmet, then the collapsible pad
members. These layers may absorb the majority of the energy of the
impact while the flexible inner liner keeps the wearer's head
stable and may absorb much less energy than it would without the
outer layer and pad members.
[0045] Removable members may also allow the user to replace pad
members that have permanently deformed, such as after an incident
in which the pad members were crushed in an impact. The removable
pad members may therefore permit the user to select sized pad
members that fit more or less closely to his or her head, allowing
for a more comfortable fit. For example, the stiffness and size of
the pad members may be selected based on the anticipated activity
of the wearer. A tighter, stiffer fit may be used for higher speed
applications (e.g., off-road vehicle driving), and a looser, more
comfortable fit may be used for slower speed applications (e.g.,
mountain biking). This may be beneficial because a comfortable fit
encourages users to wear the helmet more consistently.
[0046] The helmet may additionally comprise a flexible inner layer
or liner to be positioned between the collapsible members and the
wearer's head. The flexible inner layer may be custom-molded to
take the shape of the wearer's head on its inner surface and to
take the shape of the various collapsible pad members on its outer
surface. Thus, the flexible inner layer may be configured to
closely conform to the surfaces of the head of the wearer. The
flexible inner liner may fill or decrease the size of voids between
the collapsible members to provide additional cushioning and to
give the helmet a solid feel and improved warmth and protection.
The shaped outer surface of the flexible inner layer may be
attachable to the inner surfaces of the collapsible members, and in
some embodiments, may be removably attachable thereto. The shaped
outer surface of the flexible inner layer may thus be used to
assist the user to properly position the collapsible members
relative to the inner surfaces of the outer shell of the helmet. In
some embodiments, the inner surface of the flexible inner layer may
be shaped similar to generic surfaces of a wearer's head instead of
being custom-molded. The inner surfaces of the liner may comprise a
thin wicking fabric material within the form fitting, soft,
pliable, memory elastic foam used in other parts of the flexible
inner layer. The flexible inner layer may be designed to withstand
multiple impacts and may therefore be a reusable base for the
collapsible pad members and outer layer.
[0047] In another aspect of the present disclosure, methods of
manufacturing a multi-layered helmet are provided. These methods
may include molding a standard-shaped flexible inner layer to
conform to the inner surfaces of a plurality of collapsible members
and of a rigid outer shell. The methods may allow a user to quickly
develop a custom-fitting helmet using the head of the wearer and an
inner surface of nearly any configuration of outer shell and
collapsible members. In some embodiments, the layers of the helmet
may be removably attached to each other using pin inserts. The pin
inserts may comprise shear breakage sections configured to break
upon application of a significant shear stress caused by relative
translational or rotational movement between the layers they are
holding together. This breakage may further absorb energy of an
impact and help protect the wearer in dangerous conditions.
[0048] The present description provides examples, and is not
limiting of the scope, applicability, or configuration set forth in
the claims. Thus, it will be understood that changes may be made in
the function and arrangement of elements discussed without
departing from the spirit and scope of the disclosure, and various
embodiments may omit, substitute, or add other procedures or
components as appropriate. For instance, the methods described may
be performed in an order different from that described, and various
steps may be added, omitted, or combined. Also, features described
with respect to certain embodiments may be combined in other
embodiments.
[0049] Referring now to the figures in detail, FIGS. 1 and 2
illustrate a bicycle helmet 100 according to an exemplary
embodiment of the present disclosure. Other types of helmets (e.g.,
ski helmets and motorcycle helmets) may be implemented using the
features of helmet 100, as will be appreciated by those having
skill in the art. FIG. 1 is a perspective view of the helmet 100,
and FIG. 2 is a bottom view. The helmet 100 includes an outer shell
102 and a collapsible layer 104 comprised of multiple collapsible
pad members 106, 108, 110, 112, 114. In some embodiments, the
helmet 100 may also have a chin strap 116 and neck guard 118. These
elements are not shown in FIG. 2. The helmet 100 is shown in FIGS.
1 and 2 without a flexible inner liner interior to the collapsible
pad members 106, 108, 110, 112, 114.
[0050] The outer shell 102 may comprise a rigid, durable material.
For example, the outer shell 102 may comprise a metal such as
aluminum, a rigid plastic such as polycarbonate, or a rigid
composite such as a carbon fiber or fiberglass composite. Composite
materials may beneficially retain their shape after initial impact
due to their bonded strands maintaining a barrier to stop abrasion
and penetration after the initial impact.
[0051] The outer surface of the outer shell 102 may be configured
with graphic designs, similar to a team helmet. The outer shell 102
may take a shape generally conforming to the shape of a human head
while resisting bending and other inward deflection. In some
embodiments, the outer shell 102 may keep its shape integrity under
impacts of about 490 Newtons (50-g) to about 4093 Newtons (500-g),
and more particularly about 2942 Newtons (300-g) to about 3923
Newtons (400-g) or more. Beyond this range, the outer shell 102 may
be configured to crush on impact but maintain a consistent and
connected form (i.e., it will resist cracking and shattering) as a
protection against penetration and abrasion of the portions of the
helmet 100 beneath the surface. This consistent and connected form
may be compared to chainmail armor in that it continues to be a
consistent barrier against or stopping penetration even after it
deforms to a different shape in response to an impact. An outer
shell may need to be replaced after sustaining an impact, but at
that point it will have provided protection to the wearer by
crushing and absorbing energy that otherwise could have caused
serious (or more serious) injury to the wearer.
[0052] Because the collapsible pad members 106, 108, 110, 112, 114
may comprise a brittle material, the outer shell 102 may be
positioned exterior to the pad members to protect them from
incidental damage (e.g., scratches or small bumps). In some
embodiments, the outer shell 102 may comprise holes or other
openings for stress relief or to allow ventilation through the
shell surface. The outer shell 102 may also have protrusions and
depressions to increase stiffness, improve aerodynamics, and/or to
allow the pad members 106, 108, 110, 112, 114 to be more easily
attachable to its inner surface. For example, the shape of the
outer shell 102 may comprise slots in which specific pad members
106, 108, 110, 112, 114 are individually attachable based on their
shape. Thus, the assembly of the helmet may be simplified. In cases
where the outer shell 102 has been significantly damaged or
disfigured, the modular inner components of the helmet 100 may be
removed and reattached to another outer shell 102.
[0053] In the embodiment shown, the collapsible pad members 106,
108, 110, 112, 114 are arranged to generally cover the inner
surfaces of the outer shell 102. Broken lines are used to indicate
the presence of a pad member beneath the outer surface of the
helmet 100 in FIG. 1. The shape and size of the pad members is
provided here for illustration purposes. Typically, about four to
about twelve pad members is sufficient. In other embodiments, the
pad members may be thicker, have different boundaries, be present
in a different number or position, and so on. For example, in some
embodiments, there may be no crown member 114 to allow for
additional ventilation in the helmet 100. However, in this
exemplary embodiment, the pad members are configured to be
replaceable in the helmet 100 in positions likely to sustain an
impact. For example, the rear pad member 112 may be shaped to be
the only pad member deformed in an impact to the rear portion of
the helmet 100, so that in such an impact, the rear pad member 112
is the only pad member that requires replacement. Similarly, the
other pad members 106, 108, 110 may be shaped and positioned in the
helmet 100 in a manner that minimizes waste when the helmet 100 is
subjected to common impacts.
[0054] In some embodiments, the collapsible pad members 106, 108,
110, 112, 114 may comprise a rigid foam, such as, for example,
Styrofoam, a cellular material, expanded polystyrene (EPS) or
expanded polypropylene (EPP). The collapsible pad members 106, 108,
110, 112, 114 may alternatively or additionally comprise other
materials, such as other plastics, foams, wood composite, other
composites, or another like material. The materials used may
beneficially be light and rigid, yet crushable, foldable,
collapsible, snappable, or able to accordion under high stresses.
The pad members 106, 108, 110, 112, 114 may be beneficially
comprised of a material designed to deform at forces in a range of
about 490 Newtons (50-g) to about 1961 Newtons (200-g). Thus, upon
crushing of the outer shell 102, the pad members 106, 108, 110,
112, 114 may collapse to further absorb energy from the deflecting
outer shell 102 and prevent the wearer's head from sustaining the
full strength of the blow. Alternatively, in lower impacts that do
not deform the outer shell 102, the pad members 106, 108, 110, 112,
114 may deform before the outer shell 102 deforms to prevent
low-impact or whiplash-type injuries (such as concussions) that
tend to be more common and unreported than high-speed or
high-impact events. The collapsible pad members 106, 108, 110, 112,
114 may be formed solid or may comprise voids or varying thickness
profiles. Thus, in some embodiments they may collapse into voids
within their general shape, break down, fold, snap, accordion, or
make other similar deformation. Some of these section types are
disclosed in connection with FIGS. 10A-10K and 11, infra. The
deformation of the pad members 106, 108, 110, 112, 114 may permit
rotational or translational movement of the outer shell relative to
the flexible inner liner, or may permit rotational or translational
movement of the flexible inner liner relative to the rigid outer
shell. In at least some embodiments, the pad members may be
connected to outer shell and/or flexible inner liner in a way that
permits relative rotational and/or translational movement before
deformation of the pad members.
[0055] The crushing and movement of the outer shell and collapsible
pad members may absorb or redirect much of the initial rotational
forces in an impact because the crushing of the shell and pad
members may absorb these rotational forces. Thus, much of the
rotational movement of the head that is delivered to the brain may
be reduced, and the head and brain may rotate less and more slowly
in an impact.
[0056] FIG. 3 is a cross section of a helmet 300 according to
another embodiment of the present disclosure. This embodiment
illustrates that the helmet 300 may have a different design from
helmet 100, since helmet 300 is similar to a motorcycling helmet
with additional protection extending down the lateral sides of the
helmet, as indicated by the dashed line. The helmet 300 may
comprise a rigid outer layer 302, collapsible pad members 306, 312,
314, and a flexible inner layer 320. In this embodiment, the rigid
outer layer 302 may have similar characteristics to the outer shell
102 of FIG. 1. Likewise, the pad members 306, 312, 314 may have the
characteristics described in connection with the collapsible pad
members of FIG. 1.
[0057] The flexible inner layer 320 may comprise a moldable foam
layer that has been shaped to have an inner surface 322 with a
specified molded profile. For example, the inner surface 322 may be
molded to the shape of the surfaces of a particular wearer's head,
as further described in connection with FIG. 5. The flexible inner
layer 320 may act as a cushion for the comfort of the wearer.
Therefore, the flexible inner layer 320 may be more flexible than
the pad members 306, 312, 314. The inner layer's flexibility may
allow the wearer to more easily don and doff the helmet even though
the inner surface 322 closely follows the surface of the wearer's
head. The flexible inner layer 320 may comprise holes or voids in
its surfaces to increase ventilation through its surfaces or to
wick moisture from the wearer's head.
[0058] The flexible inner layer 320 may extend into voids 330, 332
between the collapsible pad members 306, 312, 314 using fill
members 334, 336. The fill members 334, 336 may be formed as peaks
or ridges in the outer surface 324 (see also FIG. 4) of the
flexible inner layer 320. In some embodiments, the fill members
334, 336 may completely fill the voids 330, 332, but the fill
members 334, 336 may alternatively only partially fill them (as
shown). Filling the voids 330, 332 may improve the feel of the
helmet 300 and provide additional shock absorption in the areas
between the collapsible pad members 306, 312, 314 in the event of
an impact. It may also help stabilize the collapsible pad members
306, 312, 314 in the case of an impact by keeping them securely
positioned relative to the head and the outer layer 302. The fill
members 334, 336 may also assist a user in locating the position on
the helmet at which the collapsible pad members 306, 312, 314
should be attached upon initial assembly or replacement after
deformation. See also FIG. 4, showing that the flexible inner layer
320 has pad-member-shaped recesses in its outer surface 406. In
various embodiments the fill members 334, 336 may extend partially
towards or completely into contact with the inner surface of the
outer layer 302. In other embodiments, flexible inner layer 320 is
void of fill members 334, 336 and has a generally smooth,
uninterrupted outer surface 406.
[0059] The flexible inner layer 320 may comprise a flexible
shock-absorbent material, such as a high-density foam rubber or
expanded polymer. In some embodiments, the flexible inner layer 320
may comprise moldable foams, plastics and ceramics. These foams are
preferably moldable, depending on their properties, by heating them
up (inducing flexibility), and forming them to a specific shape.
The material may then maintains its soft form once it cools. The
material may also be formed using a vacuum technique that can set
and maintain a soft and flexible shape. In another example, a
chemically activated foam material may be used that heats up when
two basic components mix and then are formed into a custom and
flexible shape that is maintained once it cools or sets.
[0060] FIG. 4 is an exploded section view of helmet 300. The rigid
outer layer 302, collapsible pad members 306, 312, 314, and
flexible inner layer 320 are separated from each other to
illustrate their individual shape characteristics. The outer layer
302 has an inner surface 400 on which the collapsible pad members
306, 312, 314 may be attached. In some embodiments, the inner
surface 400 may be textured (e.g., scored or ridged) to improve
adhesion between the pad members or other connection means (e.g.,
one side of a hook and loop fastener pad) and the inner surface
400. The inner surface 400 may also comprise openings to receive
snap-fit pins or may comprise the snap-fit pins themselves, as
shown in greater detail in connection with FIGS. 7-8. These
openings may be reinforced with pliable washer-type material or
eyelet pieces that provide reinforcement that supports and accepts
the connection of the various different helmet components. These
eyelets, rivets, and other pieces may have a plastic or rubber
liner structure and coating to give added strength and/or
reinforcement for easier and better connectivity. The outer layer
302 is not intended to be shown to scale and may be thicker than
shown, such as for purposes of accommodating the needs of various
fastening and connection devices shown herein (see, e.g., outer
shell 802 of FIG. 8).
[0061] The collapsible pad members 306, 312, 314 may each comprise
an outer surface 402 and an inner surface 404. The outer surfaces
402 may be shaped to conform to the inner surface 400 of the outer
layer 302 or to attachment surfaces (e.g., holes/grooves, or
pegs/ridges) on the inner surface 400. The inner surfaces 404 may
be shaped to provide sufficient thickness to each collapsible pad
member 306, 312, 314 to provide necessary energy absorption
characteristics for the portion(s) of the wearer's head that are
positioned adjacent thereto when the helmet 300 is being worn. For
example, the front pad member 306 may be thicker than the crown pad
member 314 when it is anticipated that higher impact energy will be
experienced by the front of the helmet 300 in a serious collision
than the crown pad member 314. Other characteristics of the pad
members 306, 312, 314 may vary from pad member to pad member as
well, such as density, crush propensity, interior void profile, and
the means by which they are individually attached to other portions
of the helmet 300. Profile shapes of the pad members 306, 312, 314
are discussed in further detail in connection with FIGS. 10A-10K
and 11, infra.
[0062] The outer and inner surfaces 402, 404 may also be configured
to accommodate attachment between the outer layer 302 and the
collapsible pad members 306, 312, 314 and/or the inner layer 320
and the collapsible pad members 306, 312, 314. Various embodiments
of attachment structures are discussed in connection with FIGS.
5-7, infra. Alternatively, the outer and inner surfaces 402, 404
may be attached to the inner surface 400 or outer surface 406 using
an adhesive, magnets, or another semi-permanent attachment means.
For example, a bonding agent (e.g., adhesive) may be used that
provides enough of a connection to keep the surfaces connected
during regular use, but can release when a threshold force is
applied to pull the bonded elements apart. In some embodiments, the
collapsible pad members 306, 312, 314 may be attachable to the
outer layer 302 and/or flexible inner layer 320 using bolts,
screws, clips, brackets, wrapped or tied wire or filament, cables,
straps, suction cups, buttons, zip ties, clamps, clasps, retaining
rings, staples, snaps, twist ties, and similar connectors. Some
arrangements may use a pocket and tab configuration wherein tabs
extending from the collapsible pad members 306, 312, 314 may be
inserted into (or rotated into) pockets in the outer shell 302. See
FIGS. 9A-9B and their related descriptions infra.
[0063] In some embodiments, the outer surfaces 402 may use a
different means or method of attachment than the inner surfaces
404. For example, the outer surfaces 402 may use snap-fit pins to
connect with the outer layer 302 and the inner surfaces 404 may use
hook and loop fasteners to connect with the flexible inner layer
320. Similarly, even if both surfaces 402, 404 use the same
attachment means, one surface may be more securely or strongly
attached than the other. For instance, the outer surface 402 may
comprise more snap-fit connectors than the inner surface 404, or
the outer surface 402 may comprise more hook and loop fastener
material (or hook and loop fastener material having stronger grip)
than the inner surface 404. The grip of a hook and loop fastener
material may be based on the length of loops or hooks in the
material. The length of the hook and loop fibers may also allow for
different degrees of movement between the layers. This may provide
added relief form rotational impacts. These embodiments may
beneficially facilitate removal of the flexible inner layer 320
without simultaneously removing the collapsible pad members 306,
312, 314, such as when the flexible inner layer 320 is removed for
cleaning or due to needing replacement. In one embodiment, the
flexible inner layer 320 may be exchanged based on the user, so
that two users may quickly exchange between flexible inner layers
that conform to their individual heads.
[0064] Alternatively, the attachment of the collapsible pad members
306, 312, 314 may be more secure to the flexible inner layer 320
than to the outer layer 302. This may potentially allow the user to
more easily identify collapsible pad members needing replacement
(such as when they crush first at their outer surfaces 402) since
the pad members 306, 312, 314 would tend to detach from the inner
surface 400 of the rigid outer layer 302 before detaching from the
flexible inner layer 320. This configuration may also be beneficial
in embodiments where users desire to exchange or customize the
outer shell, such as when a thicker or thinner design is used for
certain activities, for different connection means, or for cosmetic
reasons.
[0065] In embodiments where the connection between the outer layer
302, pad member layer (comprising the pad members, e.g., 306, 312,
314), and flexible inner layer 320 may vary in strength or
connection type from layer to layer or between specific pad members
and the outer and inner layers 302, 320, the differences in
connections may provide convenience to the user. For example, the
connection between layers may be designed to absorb different
amounts of energy, such that one layer or portion of the helmet 300
may detach the layers more easily in response to a certain force
(e.g., a rotational force or low-level impact) than to another
force (e.g., a direct/axial force or higher-strength impact). Thus,
the differing connections between layers may be a safety feature or
may make the helmet more comfortable and shock absorbent when the
helmet 300 is impacted by a lower impulse than is theoretically
sustainable by the helmet 300.
[0066] FIG. 5 illustrates an embodiment of a helmet 500 prior to
final formation of a flexible inner layer. A rigid outer layer 302
is provided attached to a plurality of collapsible pad members 306,
312, 314. An unmolded blank of a flexible inner layer 520 may
comprise a moldable foam configurable to conform to the inner
surfaces of the collapsible pad members 306, 312, 314 and the
surface of a wearer's head 550. For example, the moldable foam may
be configured to become pliable in response to heat, and the helmet
500 may be pressed upon the flexible inner layer 520 and upon
wearer's head 550 to allow the inner layer 520 to plastically
deform on contact. In one embodiment, the flexible inner layer 520
may be molded as shown in FIGS. 3-4, having fill members 334, 336.
Thus, the thickness of the flexible inner liner may vary when
measured relative to the inner surface of the rigid outer shell,
where portions such as the fill members 334, 336 are thicker than
other portions of the liner. Methods of manufacturing these helmets
are also described in more detail infra.
[0067] In another embodiment, the flexible inner layer may be
formed by a molding process where the outer layer 302 and
collapsible pad members 306, 312, 314 are positioned around the
head 550 without a flexible inner layer 520 interposed between. The
head 550 may be covered by a thin protective liner. Foam or a
gel-like substance may then be injected between the collapsible pad
members 306, 312, 314 and the wearer's head 550 which sets in place
between the pad members 306, 312, 314 and the outer layer 302 and
forms a flexible inner layer formed to the surfaces it contacts.
Using this process, the flexible inner layer may be easily formed
around connection pins extending from the collapsible pad members
306, 312, 314 (see FIGS. 7-8), and the flexible inner layer may
more readily fill spaces between the pad members 306, 312, 314.
[0068] FIGS. 6-8 are partial cross-sectional illustrations of
various ways in which multiple layers of a helmet may be attached
to each other. In FIG. 6, the rigid outer layer 602, collapsible
pad member 606, and flexible inner layer 620 are attached to each
other using hook and loop fastener material 610, 612. The hook and
loop fastener material 610 between the outer layer 602 and the
collapsible pad member 606 may have different surface coverage,
gripping strength, and positioning than the hook and loop fastener
material 612 between the collapsible pad member 606 and the
flexible inner layer 620. In some embodiments, the hook and loop
fastener material 610, 612 may entirely cover the surfaces of the
layers 602, 606, 620 that come into contact with each other, and,
as discussed above, the hook and loop fastener material 610, 612
may have different grip strengths for different portions of the
helmet or for individual collapsible pad members. The hook and loop
fastener material 610, 612 is typically attached to portions of the
helmet by an adhesive or by sewing.
[0069] Some layers may comprise ridge and groove fasteners in
addition to, or in place of, hook and loop fasteners. For example,
the flexible inner layer 620 and collapsible pad member 606 may
comprise one or more interlocking ridge 650 and groove 652. The
ridge and groove fasteners may comprise materials that differ from
the remainder of the layers (e.g., the flexible inner layer 620 and
collapsible pad member 606), such as comprising a flexible plastic
that can securely yet removably interlocking ridges 650 and grooves
652 when they are pressed together. The ridges and grooves may be
releasably attachable to each other to facilitate disassembly and
replacement of collapsible pad members or other modular components
of the helmet. Including ridge and groove fasteners may increase
the strength of the connection between two layers and absorb impact
energy if they disconnect in response to an applied force. In some
embodiments, the ridge and groove fasteners may connect a
collapsible pad member to the outer shell, and in some cases the
ridge and groove fasteners may be the only attachment means
connecting the layers.
[0070] FIG. 7 illustrates an embodiment where the rigid outer layer
602, collapsible pad member 606, and flexible inner layer 620 are
connectable to each other using snap-fit connectors 700. The
snap-fit connectors 700 extend from surfaces of the flexible inner
layer 620 and the outer layer 602 toward the collapsible pad member
606 at positions corresponding with openings 702 in the collapsible
pad member 606. The openings 702 may correspond to positions on the
collapsible pad member 606 that securely attach the collapsible pad
member 606 to the outer layer 602 and the flexible inner layer 620.
The openings 702 and corresponding snap-fit connectors 700 may be
flexible enough to resiliently receive (i.e., snap into) each
other, but then cause an interference fit that keeps the layers
linked to each other unless a sufficient axial force is applied to
a connector 700 to remove it from its opening 702. The snap-fit
connection between the connectors 700 and the openings 702 may
differ in each collapsible pad member 606 of the helmet, and may be
stronger between different layers as well. For example, the
snap-fit connection between the outer layer 602 and the pad member
606 may require more force to disconnect than the snap-fit
connection between the flexible inner layer 620 and the pad member
606.
[0071] FIG. 8 illustrates another embodiment of a snap-fit between
layers of a helmet of the present disclosure. A rigid outer shell
802 is external to a collapsible pad member 806 which is in turn
external to a flexible inner layer 820. Snap-fit pin inserts 800
are disposed between the layers and are insertable into cavities
822 in each layer. The snap-fit pin inserts 800 and cavities 822
may be similarly received by each other as the snap-fit connectors
700 and openings 702 of FIG. 7. The pin inserts 800 may also
comprise a shear breakage section 805 configured to break in
response to an applied shear force. For example, the pin inserts
800 may be configured to break in response to sufficient relative
rotational movement of the outer shell 802 and the collapsible pad
member 806 to apply the shear force to the shear breakage sections
805 of the pin inserts 800. These sections 805 may provide
additional resistance to relative rotational movement of the layers
without completely restricting the relative rotational movement
upon reaching a sufficient threshold shear stress. These sections
805 may absorb energy in the helmet upon breakage and help to
lessen the forces experienced by the wearer's head. The pin inserts
800 may be removable or exchangeable in the cavities 822, so some
portions of the helmet may be configured to have greater resistance
to breakage than other potions, the pin inserts 800 may be
replaceable upon breakage, and different pin inserts 800 may be
used between each layer to give the helmet different attachment and
breakage properties in inner areas of the helmet than in areas
further outward.
[0072] FIGS. 9A and 9B show an exemplary collapsible pad member 900
using tab and pocket connectors. The collapsible pad member 900 may
be one of pad members 106, 108, 110, 112, 114, 306, 312, 314, 606,
806 shown elsewhere herein. Connector tabs 902 extend from the
periphery of the pad member 900 in positions configured to rotate
into pockets 904 in the inner surface of a rigid outer shell 906.
The tabs 902 and pockets 904 may be configured to slide or snap
into position upon rotation of the collapsible pad member 900 with
the tabs 902 adjacent to the pockets 904. While three tabs 902 are
shown in these figures, other pad members or other embodiments of
the pad member 900 shown may comprise more or fewer tabs 902 with a
corresponding number of pockets 904. Use of tab and pocket
connectors may allow users to quickly and easily insert and remove
collapsible pad members 900. The tabs 902 may also be configured to
break upon a sufficient impact, thereby absorbing some of the
energy of the impact in addition to other energy absorption
elements of the helmet.
[0073] FIGS. 10A-10K show exemplary cross-sectional profiles of
collapsible pad members (e.g., pad members 106, 108, 110, 112, 114,
306, 312, 314, 606, 806). The profiles illustrate how various
embodiments may include shape profiles in addition to other
features (e.g., density, thickness, and position) in order to
affect the crush and deformation characteristics of the pad
members. The profiles may each comprise a lower surface 1000 and an
upper surface 1002. Generally, the lower surface 1000 is relatively
smooth and configured to conform to the inner surface of a rigid
outer layer. For example, the lower surface 1000 may be partially
spherical or ellipsoidal to follow the inner surface of a partially
spherical or ellipsoidal rigid outer layer. The upper surface 1002
is relatively textured and may comprise peaks, ridges, cones,
valleys, and other shapes similar to those pictured in these
figures. The upper surface 1002 is typically oriented to face
inward in a helmet. In some embodiments, the lower surface 1000 may
also be textured, as illustrated in FIG. 10D. Generally, increasing
the thickness of the ridges or peaks increases the rigidity of the
collapsible pad members and therefore makes them more resistant to
deformation. Layers of pad members may be linked or stacked to form
a single structure, such as the structure shown in FIG. 11. Tests
by the inventors indicate that preferable profile embodiments
include the embodiments of FIGS. 10D, 10G and 11 which are
measurably more shock absorbent under multiple tests than other
examples shown.
[0074] A profile of FIG. 10A may be referred to as having a
semicircular pattern. Other patterns may include rounded sawtooth
(FIG. 10B), spaced sawtooth (FIG. 10C), double spaced sawtooth
(FIG. 10D), elbow (FIG. 10E), narrow rectangular (FIG. 10F), broad
rectangular (FIG. 10G), jagged triangular (FIG. 10H), angled
triangular (FIG. 10I), truncated pyramidal (FIG. 10J), pyramidal
(FIG. 10K), and zigzag (FIG. 11). In one embodiment, a "bird nest"
design may be used that features overlapping and intertwining
segments. While the characteristics of collapsible members having
these profiles may vary based on their rigidity, materials of
construction, thickness, and other features, for the sake of
example in this disclosure, the embodiments of FIGS. 10A-10D,
10E-10G, and 10H-10K may be characterized as forming collapsible
members that permanently deform by crushing, and the embodiments of
FIGS. 10D-10E and 11 may be said to be collapsible members that
deform by folding, breaking, or snapping. Assuming that each
profile is constructed of the same material, these are likely
outcomes of how each of the profiles will react to a powerful
impulse. A breakage or snapping connotes that the profile
dissipates energy on impact by fracturing or breaking, and a
crushing or folding describes dissipation of energy on impact by
changing shape, absorbing an impact, crushing voids or flexible
material spaced within the profile, or the like. The embodiments of
FIGS. 10D-10E and 11 may beneficially provide lateral dispersion of
energy in reaction to a vertical applied force and may therefore be
more energy absorbent than other profiles. Additionally, while FIG.
11 is the only example shown having multiple tiers or staggered
levels, any of the embodiments of FIGS. 10A-10K may be modified to
support multiple crush layers within a single collapsible
member.
[0075] According to some embodiments, a method of manufacturing a
multi-layered helmet for deformably absorbing an impact to a head
of a wearer may be performed by providing a rigid outer shell, a
plurality of collapsible members, and a flexible inner liner. The
rigid outer shell may have an inner surface to which the plurality
of collapsible members may be attached. The collapsible members may
be permanently deformable to absorb impact energy in response to a
force applied to the rigid outer shell. The flexible inner liner
may be attached to the inner surfaces of the plurality of
collapsible members.
[0076] In some cases, the attachment between the collapsible
members and the outer shell and/or flexible inner liner may be
removable attachment, such as by hook and loop fasteners, pin
inserts, snap-fit connectors, interlocking ridges and grooves, or
other removable attachment means. For example, the method may
include providing a plurality of pin inserts, forming a plurality
of cavities or openings in the plurality of collapsible members
that are shaped to receive the pin inserts, and inserting the pin
inserts into the plurality of cavities and into the rigid outer
shell and flexible inner liner. The pin inserts then removably
secure the collapsible members to the rigid outer shell and
flexible inner liner. In some embodiments the removable attachment
between the collapsible members and the rigid outer shell is more
secure or more difficult to detach than the removable attachment
between the collapsible members and the flexible inner liner.
[0077] The method may also include shaping the flexible inner liner
to conform to the inner surfaces of the plurality of collapsible
members and to a surface of the head of the wearer. Thus, the
flexible inner liner may comprise expansion portions that expand
into (or are molded into) voids between the plurality of
collapsible members and the head of the wearer. An unfinished
flexible inner liner may for example be heated to a temperature
allowing at least temporary plastic deformation, then pressed into
contact with the inner surfaces of the collapsible members and/or
the rigid outer shell. The unfinished flexible inner liner may then
deform upon contact, filling grooves and apertures on the surface
(or receiving protrusions thereon) of the collapsible members and
at least partially retain the molded shape after cooling or curing
(i.e., stiffening). The material used in the flexible inner liner
may be a lightweight foam or gel material that will maintain its
form and shape, but also have elastic flexibility and stretch to
provide comfort. The wearer's head may be simultaneously pressed
against the inner surface of the unfinished flexible inner liner to
mold the liner into conformity with the head surfaces, though in
some embodiments, the head contacting surfaces of the flexible
inner liner may be separately formed or molded at a different
time.
[0078] In another embodiment, the flexible inner liner may be
formed by covering or filling the voids and surfaces around the
collapsible members with shape-filling material, such as a fluid,
foam, paste, gel, clay-like material, or other material that can
take the shape of the interior of the helmet. The shape-filling
material may be injected or pushed between the collapsible members,
between the head of the wearer and the collapsible members, or by
another method known in the art. In some arrangements, a foam
material is used that may be in a flowable form stored under
pressure in a canister. The flowable material can be extruded from
the canister and placed in a soft foam liner. The material may then
set or cure to have the desired characteristics. Curing or setting
of the material may be through a chemical reaction, light
activation, or air activation, depending on the particular
formation of the foam material. The shape-filling material may be
part of the finished flexible inner liner by forming the shape of
the outer surface of the inner liner that faces the collapsible
members, and also potentially forming the shape of the inner
surface that faces the wearer. By using a shape-filling material,
the helmet may be made more solid and have a more precise fit to
the wearer and to the inner surfaces of the collapsible members and
outer shell.
[0079] In one embodiment, the liner material may be a lightweight
synthetic elastic material that can be designed in pocket form. The
pocket form may be able to have expandable foam injected into the
picket such that the soft foam liner can take the size and shape of
an individual's head. For example, the liner may be fitted and
filled with foam in a stationary hard mold simulating a rigid outer
shell to facilitate proper fit and fill to the size and shape of
the individual wearer's head. The flexible inner liner may also
comprise a material at its surface that is soft, breathes, and
wicks away moisture. The shape of the liner may include vents for
air circulation.
[0080] The helmet may be manufactured with different types of
collapsible members being attached at different positions in the
helmet. For example, one portion of the collapsible members having
a greater rigidity than another portion may be attached to inner
surfaces of the outer shell that require additional rigidity in
their energy absorption characteristics. In some examples, the
collapsible members themselves may have custom fit features formed
therein as opposed to having the custom fit features formed solely
in the flexible liner as discussed above.
[0081] When one of the collapsible members is deformed or damaged,
such as after an impact, the method of replacing the collapsible
member may include a step of detaching the flexible inner liner
from the inner surfaces of the plurality of collapsible members,
then detaching a first consumed first collapsible member from the
inner surface of the rigid outer shell or the outer surfaces of the
flexible inner liner. The consumed collapsible member may be
individually detachable from the rest of the collapsible members.
Next, the consumed first collapsible member may be replaced by a
second collapsible member that has an equivalent shape to the first
collapsible member. The second collapsible member may thus be a
replacement part for the helmet that matches or closely imitates
the shape and other characteristics of the first collapsible
member. Finally, the flexible inner liner may be reattached to the
inner surfaces of the plurality of collapsible members.
[0082] In another embodiment, the flexible inner liner may be
removed from the helmet simultaneously with the collapsible
members, which are attached to the outer surface of the flexible
inner liner. Thus, the flexible inner liner and the collapsible
members may be removed together from the outer shell. This may be
beneficial when the collapsible members are likely to become
detached from the outer shell upon their deformation and yet are
likely to remain attached to the flexible inner liner at the same
time. This embodiment may also facilitate replacement of the
consumed collapsible member since the flexible inner liner may have
extension portions that extend around the area of the flexible
inner liner that is supposed to receive the replacement collapsible
member. Therefore, these extension portions may act as a guide for
the positioning of the new collapsible member prior to reinsertion
of the flexible inner liner into the helmet.
[0083] FIGS. 12A-12M show photographs of exemplary test members for
the profile shapes of FIGS. 10A-10K and 11. FIG. 12A is a control
member of a solid block of foam, and 12B-12M are members that
correspond with the profile shapes of FIGS. 10A-10K and 11,
respectively. In FIGS. 12A-12M, the foam members were tested by
dropping a ball from a height of 0.5 meters and 1.0 meters onto
foam members having the profiles shown comprised of 2-pound or
3-pound density styrofoam. The figures show the permanent
deformation and crush of each type of profile after testing was
completed. Thus, each figure shows the effects of an equivalent
impact on each profile shape. The embodiment of FIG. 12M was
particularly crushed and broke or folded in response to the impact
of the test ball. The following table displays test results
obtained when testing the foam members of FIGS. 12A-12M.
TABLE-US-00001 2-lb. 2-lb. 3-lb. 3-lb. Member - Member - Member -
Member - Module Label 0.5 m Drop 1.0 m drop 0.5 m drop 1.0 m drop
Control 55.0 88.2 77.1 113.0 Module 1A 58.5 334.0 67.5 132.0 2A
59.5 308.0 61.5 114.5 3A 212.5 553.0 94.0 406.5 4A 46.0 306.0 52.5
107.0 5A 122.0 479.0 89.0 327.5 6A 56.0 162.5 54.5 225.5 7A 54.0
99.5 57.0 120.5 8A 227.0 484.0 89.0 377.5 8B 64.0 395.5 67.5 163.0
10A 50.0 312.0 45.0 99.0 11A 153.0 402.0 69.0 441.0 12A 235.5 549.5
220.0 592.0
[0084] The module labels are shown in FIGS. 12A-12M. The tabulated
data is the maximum g-forces (measured in g-scale) transferred from
the dropped ball through the module to an accelerometer. Thus, the
foam members tested that improved protection over the block-shaped
control module have lower g-forces registered than the control
module. This means that module 10A (corresponding with FIG. 12M)
had the best performance, followed by modules 4A and 6A
(corresponding with FIGS. 12E and 12G, respectively).
[0085] FIGS. 13A-13B show another embodiment of a collapsible
member 1300 configured to be attachable to an outer shell of a
helmet of another embodiment of the present disclosure. The member
1300 comprises a first impact layer 1302 and a second impact layer
1304. The second impact layer 1304 may be designed to crush or
otherwise permanently deform when a force that could cause a head
injury is applied. For example, as illustrated in FIG. 13B, when an
impact that is sufficient to cause head injury is applied to the
second impact layer 1304, the material may collapse and crush, and
in the process may absorb the energy from the impact and protect
the wearer's head. Should the wearer experience a higher force
impact, the second impact layer 1304 may collapse and allows the
wearer's head to engage the first impact layer 1302 to further
protect the wearer's head and absorb additional energy.
[0086] As illustrated in FIGS. 13A and 13B, the second impact layer
1304 may have a "bird nest"-like design that features overlapping
and intertwining collapsible segments. The bird nest configuration
may allow the second impact layer 1304 to absorb impact by crushing
onto itself. The second impact layer 1304 may also comprise
segments configured to collapse, crush, or have stress points
designed to break in a sufficient impact. The impact layers may be
molded and made from the same material in one piece or may be
attached to each other.
[0087] FIG. 14 illustrates another embodiment of a second impact
layer 1304 of FIG. 13. The second impact layer 1304 may comprise
rods, pistons, and/or core/tubular structures 1400. These
structures 1400 may be woven together in the bird nest
configuration or may be freestanding. The structure and shape of
the structures 1400 may allow material to collapse, crush,
accordion, and break apart to absorb energy from an impact. The
tiered pillar design may allow variable resistance to crushing and
other deformation or breaking, so that the structures 1400 may
break or crush more gradually and absorb the energy of both lesser
and greater impacts.
[0088] FIG. 15 illustrates another embodiment of a second impact
layer 1304 of FIG. 13. In this case, the second impact layer 1504
comprises a plurality of interlinked cellular structures. The
structures may have a honeycomb design having an irregular surface
shaped to conform to the outer surface of a flexible inner liner,
as shown generally by the dashed line. The thickness of the
cellular structures may also vary based on the area of the helmet
in which the pad member having the second impact layer 1504 may be
attached. For example, a thicker layer of cellular structures may
be positioned where the wearer's head is most likely to sustain a
low-force impact. The cellular structures may be configured to
collapse and crush into contact with each other and the first
impact layer 1502.
[0089] FIGS. 13A-13B, 14, and 15 illustrate how collapsible pad
members (e.g., pad members 106, 108, 110, 112, 114, etc.) may be
configured for withstanding a single impact and then would be need
to replaced. These pad members may be easily and inexpensively
produced so that the helmet may be used in many impacts at full
capacity and without frustrating the user who needs a replacement
pad member.
[0090] The previous description of the disclosure is provided to
enable a person skilled in the art to make or use the disclosure.
Various modifications to the disclosure will be readily apparent to
those skilled in the art, and the generic principles defined herein
may be applied to other variations without departing from the
spirit or scope of the disclosure. Throughout this disclosure the
term "example" or "exemplary" indicates an example or instance and
does not imply or require any preference for the noted example.
Thus, the disclosure is not to be limited to the examples and
designs described herein but is to be accorded the widest scope
consistent with the principles and novel features disclosed
herein.
* * * * *