U.S. patent application number 14/315080 was filed with the patent office on 2014-12-25 for layered protective structures.
The applicant listed for this patent is HIP-Tec, LLC. Invention is credited to Tom Feiten, Nick Turner.
Application Number | 20140373257 14/315080 |
Document ID | / |
Family ID | 52109710 |
Filed Date | 2014-12-25 |
United States Patent
Application |
20140373257 |
Kind Code |
A1 |
Turner; Nick ; et
al. |
December 25, 2014 |
LAYERED PROTECTIVE STRUCTURES
Abstract
Protective structures that may be used in various protective
gear items, such as helmets and the like. In some embodiments, the
protective structure may comprise a layered structure having three
distinct layers. The various layers may be selected, arranged, and
configured to provide for improved protection at multiple
velocities, such as high velocity impacts and low velocity impacts.
Some embodiments may also, or alternatively, be configured to
provide improved protection and/or durability for multiple impacts
at the same portion of the helmet over time.
Inventors: |
Turner; Nick; (Ogden,
UT) ; Feiten; Tom; (Truckee, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
HIP-Tec, LLC |
Ogden |
UT |
US |
|
|
Family ID: |
52109710 |
Appl. No.: |
14/315080 |
Filed: |
June 25, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61839314 |
Jun 25, 2013 |
|
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Current U.S.
Class: |
2/414 |
Current CPC
Class: |
A42B 1/063 20130101;
A42B 3/125 20130101 |
Class at
Publication: |
2/414 |
International
Class: |
A42B 3/12 20060101
A42B003/12; A42B 3/00 20060101 A42B003/00 |
Claims
1. A helmet, comprising: a layered protective structure shaped to
fit over a head of an individual, the layered protective structure
comprising: a first layer; a second layer positioned internally of
the first layer, wherein the second layer comprises a more rigid
and less compressible material than the first layer, and wherein a
thickness of the second layer is less than a thickness of the first
layer; and a third layer positioned internally of the second layer,
wherein the third layer comprises a compressible, resilient
material configured to compress and rebound upon being deformed,
and wherein a thickness of the third layer is greater than a
thickness of the second layer.
2. The helmet of claim 1, wherein the first layer comprises a
crushable material.
3. The helmet of claim 2, wherein the crushable material comprises
a crushable foam material.
4. The helmet of claim 3, wherein the crushable foam material
comprises at least one of expanded polystyrene and expanded
polypropylene.
5. The helmet of claim 1, wherein the second layer comprises a
plastic material.
6. The helmet of claim 1, wherein the second layer comprises at
least one of acrylonitrile butadiene styrene plastic, fiberglass,
and carbon fiber material.
7. The helmet of claim 1, wherein the third layer comprises at
least one of an ethylene-vinyl acetate foam and a non-newtonian
foam.
8. The helmet of claim 1, wherein the second layer comprises a
plurality of openings each defined by a plurality of crimped
walls.
9. The helmet of claim 1, wherein the first layer is positioned
adjacent to the second layer, and wherein the second layer is
positioned adjacent to the third layer.
10. The helmet of claim 1, wherein the first layer has a density
greater than a density of the third layer.
11. The helmet of claim 1, further comprising an outer shell
positioned adjacent to the layered protective structure such that
the layered protective structure is positioned within the outer
shell.
12. A layered protective structure for both high and low velocity
impacts configured to be used in a protective gear item, the
layered protective structure comprising: an outer layer comprising
a first density; an inner layer comprising a compressible,
resilient material configured to compress and rebound upon being
deformed by an impact, wherein the inner layer comprises a second
density, and wherein the second density is less than the first
density; and a middle layer positioned in between the inner layer
and the outer layer, wherein the middle layer comprises a rigid
material configured to spread energy from an impact across a larger
area on the inner layer to dissipate energy transfer through the
inner layer from the impact, wherein the middle layer comprises a
third density, and wherein the third density is greater than the
first density and the second density.
13. The layered protective structure of claim 12, configured to
permanently deform upon receipt of a high velocity impact, wherein
the outer layer is configured to avoid permanent deformation upon
receipt of low velocity impacts.
14. The layered protective structure of claim 12, wherein the
middle layer comprises a material configured to inhibit penetration
into the middle layer by impacts with sharp objects.
15. The layered protective structure of claim 12, wherein the outer
layer has a thickness of between 3 mm and 30 mm.
16. The layered protective structure of claim 15, wherein the outer
layer has a thickness of between 10 mm and 20 mm.
17. The layered protective structure of claim 12, wherein the outer
layer has a density of between 30 g/l and 80 g/l.
18. The layered protective structure of claim 12, wherein the inner
layer has SHORE-A hardness value of between 20 and 70.
19. The layered protective structure of claim 12, wherein the
middle layer has a thickness of between 1 mm and 2 mm.
20. The layered protective structure of claim 12, wherein the inner
layer has a thickness of between 3 mm and 20 mm.
21. The layered protective structure of claim 20, wherein the inner
layer has a thickness of between 5 mm and 10 mm.
22. The layered protective structure of claim 12, further
comprising an outer shell positioned to encase the layered
protective structure therein.
23. A helmet, comprising: an outer shell; and an inner shell
comprising a layered protective structure positioned within the
outer shell, the layered protective structure comprising: an outer
layer comprising a crushable foam material having a density of
between about 20 g/l and about 85 g/l, wherein a thickness of the
outer layer is between about 5 mm and about 30 mm; an inner layer
comprising a compressible, resilient material configured to
compress and rebound upon being deformed by an impact, wherein a
thickness of the inner layer is between about 5 mm and about 15 mm,
and wherein the inner layer comprises a material having a SHORE-A
hardness value of between about 20 and about 70; and a middle layer
comprising at least one of acrylonitrile butadiene styrene plastic,
fiberglass, and carbon fiber material, wherein a thickness of the
inner layer is between about 1 mm and about 2 mm.
24. The helmet of claim 23, wherein the inner layer comprises at
least one of an ethylene-vinyl acetate foam and a non-newtonian
foam.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C.
.sctn.119(e) of U.S. Provisional Patent Application No. 61/839,314
filed Jun. 25, 2013 and titled "LAYERED PROTECTIVE STRUCTURES FOR
PROTECTIVE GEAR," which application is incorporated herein by
reference in its entirety.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] Non-limiting and non-exhaustive embodiments of the
disclosure are provided herein, including various embodiments of
the disclosure illustrated in the figures listed below.
[0003] FIG. 1 depicts an embodiment of a helmet according to one
embodiment.
[0004] FIG. 2 depicts a cross-sectional view of the layered, inner
shell of FIG. 1 taken along line 2-2 in FIG. 1.
[0005] FIG. 3 depicts an exploded view of the layered, inner shell
of FIG. 2.
[0006] FIG. 4 is a graph depicting the results of an impact case
study involving a helmet incorporating a layered, inner shell
according to one embodiment of the invention compared with other
helmets not incorporating the inventive subject matter disclosed
herein.
[0007] FIG. 5 is a graph depicting the g-forces associated with a
first impact on a helmet incorporating a layered, inner shell
according to one embodiment of the invention compared with other
helmets not incorporating the inventive subject matter disclosed
herein.
[0008] FIG. 6 is a graph depicting the g-forces associated with a
second impact on a helmet incorporating a layered, inner shell
according to one embodiment of the invention compared with other
helmets not incorporating the inventive subject matter disclosed
herein.
[0009] FIG. 7 is a graph depicting the g-forces associated with a
third impact on a helmet incorporating a layered, inner shell
according to one embodiment of the invention compared with other
helmets not incorporating the inventive subject matter disclosed
herein.
[0010] FIG. 8 depicts an embodiment of a middle layer usable with
certain embodiments of layered protective structures, the middle
layer comprising a plurality of crimped openings.
[0011] FIG. 9 depicts another embodiment of a middle layer usable
with certain embodiments of layered protective structures.
[0012] In the following description, numerous specific details are
provided for a thorough understanding of the various embodiments
disclosed herein. The systems and methods disclosed herein can be
practiced without one or more of the specific details, or with
other methods, components, materials, etc. In addition, in some
cases, well-known structures, materials, or operations may not be
shown or described in detail in order to avoid obscuring aspects of
the disclosure. Furthermore, the described features, structures, or
characteristics may be combined in any suitable manner in one or
more alternative embodiments.
DETAILED DESCRIPTION
[0013] Embodiments may be best understood by reference to the
drawings, wherein like parts are designated by like numerals
throughout. It will be readily understood that the elements,
materials, and components of the present disclosure, as generally
described and illustrated in the drawings herein, could be arranged
and designed in a wide variety of different configurations and
embodiments. Thus, the following more detailed description of the
embodiments of the apparatus is not intended to limit the scope of
the disclosure, but is merely representative of possible
embodiments of the disclosure. In some cases, well-known
structures, materials, or operations are not shown or described in
detail in order to avoid obscuring aspects of the disclosure.
Furthermore, the described features, structures, steps, or
characteristics may be combined in any suitable manner in one or
more alternative embodiments and/or implementations.
[0014] The present disclosure provides various embodiments of
layered shell configurations that may be used in various protective
gear items, such as helmets. In some embodiments, the layered shell
may be configured to provide for improved protection at multiple
velocities. For example, some embodiments may be configured to
provide improved impact protection during relatively high velocity
impacts and also relatively low velocity impacts. Some embodiments
may be also, or alternatively, be configured to provide improved
protection and/or durability for multiple impacts at the same
portion of the helmet over time. Some embodiments may also allow
for providing a substantially thinner layer of protective structure
than traditional helmets or other protective gear, while still
providing one or more of the improved impact protection features
mentioned herein.
[0015] Some embodiments may comprise helmets, such as helmets for
use in motorcycling, skiing, snowboarding, skateboarding, and the
like, comprising an interior structure that provides significant
reduction in g-force impacts to the head from high velocity and low
velocity impacts. In some embodiments, the helmet may also, or
alternatively, provide significantly more multiple impact
protection than currently available protective interior
structures.
[0016] Some embodiments may comprise a protective structure
comprising multiple layers of different materials having different
thicknesses and densities that are arranged and configured to
interact with one another in a manner so as to cushion the head (in
embodiments incorporated into helmets) and protect the head from
impacts by dissipating energy from both the outside of the helmet
(area of impact) and from the interior of the helmet by reducing
the deceleration velocity of the head during an impact. Some
embodiments, as described in greater detail below, may comprise
three distinct layers each comprising different materials arranged
relative to one another and comprising preselected thicknesses that
improve impact protection.
[0017] In some such embodiments, the outermost layer may comprise a
relatively thick layer made up of a crushable foam material or
another material having similar properties. The middle layer may
comprise a relatively thin layer made up of a hard plastic material
or another material having similar properties configured to spread
energy from an impact across a larger area to dissipate the energy
transfer to the head associated with the impact. The innermost
layer may comprise a material having properties that allow it to
compress and rebound, preferably with little deterioration in shock
absorbing properties, such as an ethylene-vinyl acetate (EVA) foam
or a non-newtonian foam such as a PORON.RTM. foam. Although the
thickness of the inner layer may vary depending upon the desired or
intended impact protection characteristics, preferably the
thickness of the inner and outer layers are both substantially
greater than the thickness of the middle layer of the protective
structure. In some embodiments, the thickness of the inner layer
may be in between that of the outermost layer and the middle layer
of the protective structure.
[0018] Additional details of certain embodiments and
implementations will now be discussed in greater detail with
reference to the accompanying drawings. FIG. 1 depicts an
embodiment of a helmet 100 according to one embodiment of the
invention. Helmet 100 comprises an outer shell 110 and an inner
protective structure comprising an inner shell 120. As described in
greater detail below, inner shell 120 may comprise a layered
protective structure. In addition, inner shell 120 may be
configured to conform to the shape, venting pattern, and/or
retention system of outer shell 110. In such embodiments, inner
shell 120 may be configured to be retro-fittable with an existing
outer shell. Alternatively, inner shell 120 may be modular such
that various different inner shells having differing impact
protection characteristics may be inserted into a single outer
shell in accordance with particular intended uses of the helmet or
other protective gear. Of course, in other embodiments and
implementations, the inner shell may be manufactured together with
the outer shell.
[0019] FIG. 2 depicts a cross-sectional view of an embodiment of a
layered protective structure comprising an inner shell that may be
used in a helmet or another item of protective gear. As shown in
this figure, the depicted inner shell 120 comprises three separate
layers, each made up of a different material having different
properties, thicknesses, and/or densities. In certain preferred
embodiments, each of the three layers is made up of a different
material, comprises a different thickness, and comprises a
different density.
[0020] More particularly, inner shell 120 comprises an outer layer
122, a middle layer 124, and an inner layer 126. Preferably, the
materials and thicknesses of the three layers are selected and
arranged to interact with one another during an impact so as to
improve impact protection characteristics. In some embodiments, the
materials and thicknesses of the three layers may be selected and
arranged to interact with one another during an impact so as to
improve impact protection characteristics associated with both high
velocity and low velocity impacts. Additionally, or alternatively,
the materials and thicknesses of the three layers may be selected
and arranged to interact with one another during an impact so as to
improve impact protection characteristics associated with repeated
impacts at the same, or at least generally the same, location on
the helmet over time.
[0021] In some preferred embodiments, the density of the
material(s) making up middle layer 124 is greater than the density
of the material(s) making up either of the other two layers. Middle
layer may comprise a relatively rigid, hard material, such as a
hard plastic material. In some such embodiments, the density of
outer layer 122 is greater than the density of inner layer 126. It
has been discovered that such configurations result in an improved
energy transfer and absorption between the three layers that
results in improved impact protection.
[0022] In some embodiments, outer layer 122 may comprise a material
having energy absorption characteristics, such as a foam material.
Preferably, outer layer 122 comprises a compressible material. In
some such embodiments, outer layer 122 may comprise a crushable
foam material. Examples of suitable materials for outer layer 122
that have desired energy absorption characteristics include EPS
(expanded polystyrene) and EPP (expanded polypropylene). In some
preferred embodiments, the density of the material making up outer
layer 122 may be between about 20 g/l and about 85 g/l. In some
such embodiments, the density of the material making up outer layer
122 may be between about 40 g/l and about 85 g/l. In some such
embodiments, the density of the material making up outer layer 122
may be between about 30 g/l and about 80 g/l. In some such
embodiments, the density of the material making up outer layer 122
may be between about 20 g/l and about 40 g/l. In some such
embodiments, the density of the material making up outer layer 122
may be between about 60 g/l and about 85 g/l.
[0023] In some preferred embodiments, the thickness of outer layer
122 may be between about 5 mm and about 30 mm. In some such
embodiments, the thickness of outer layer 122 may be between about
10 mm and about 30 mm. In some such embodiments, the thickness of
outer layer 122 may be between about 10 mm and about 20 mm. It
appears that these ranges and materials provide for improved
protection from low velocity impacts, high velocity impacts, and
multiple impacts.
[0024] In some embodiments, middle layer 124 may comprise a
relatively rigid, non-compressible, and thinner layer of material.
For example, middle layer 124 may comprise an acrylonitrile
butadiene styrene (ABS) plastic or another material with similar
properties, such as a fiberglass, carbon fiber material, and the
like. In some preferred embodiments, middle layer 124 may comprise
a thickness of between about 1 mm and about 2 mm. As described in
greater detail below, preferably middle layer 124 is configured and
arranged to isolate and/or spread forces and accompanying energy
associated with exterior impacts from/across inner layer 126.
Middle layer 124 may also be configured to serve as a barrier to
protect against penetration by sharp objects, such as rocks, wood
splinters, and the like. Middle layer 124 may comprise an at least
substantially smooth surface, and may further, or alternatively,
comprise a support in the form of a supported edge crimp, which may
be useful for ventilation. Such a crimp or crimps may also be
useful in increasing the rigidity of middle layer 124 and/or
improving the functionality of the protective structure by
improving the ability of the middle layer 124 to spread or
otherwise distribute forces between the outer layer 122 and the
inner layer 126, as discussed below in connection with FIG. 8.
[0025] In some embodiments, inner layer 126 comprises a
compressible, resilient material, preferably configured to avoid
crushing deformation that would be associated with certain
preferred embodiments of outer layer 122 during high velocity
impacts. Suitable materials include, for example, ethylene-vinyl
acetate (EVA) foam or a non-newtonian foam such as a PORON.RTM.
foam. In some preferred embodiments, inner layer 126 comprises a
softer material than the material making up either of the other two
layers, so as to provide cushion to a head or other body portion
during an impact. In some preferred embodiments, inner layer 126
may comprise a thickness of between about 3 mm and about 20 mm. In
some such embodiments, inner layer 126 may comprise a thickness of
between about 5 mm and about 15 mm. In some such embodiments, inner
layer 126 may comprise a thickness of between about 5 mm and about
10 mm. In embodiments comprising an inner layer of EVA, such
material making up the inner layer 126 may have a SHORE-A hardness
value of between about 20 and about 70.
[0026] FIG. 3 depicts an exploded view of the layered, inner shell
of FIG. 2. As can be better seen in this figure, middle layer 124
is substantially thinner than either of the other two layers. In
addition, as mentioned above, in some embodiments, outer layer 122
may be thicker than inner layer 126. As also mentioned above, in
certain preferred embodiments, outer layer 122 comprises a
crushable material, inner layer 126 comprises a material than is
resiliently deformable such that crushing or permanent deformation
is less likely to occur in inner layer 126 than in outer layer 122,
and middle layer 124 comprises a rigid, non-deformable material
configured to absorb and isolate certain impacts from outer layer
122 to inner layer 126 and/or spread such impacts across a greater
area from outer layer 122 to inner layer 126 to dissipate the
forces associated with the impacts.
[0027] This combination of layers of different materials having
preselected properties better protects against both high and low
velocity impacts to a helmet or other protective gear item. In some
embodiments, this combination of layers of different materials
having preselected properties also provides improved protection
against multiple low-velocity impacts. Without being limited by
theory, it is thought that these improvements, and others, may be
obtained as follows.
[0028] During relatively high velocity impacts, outer layer 122,
which provides impact absorption from the impact arriving from the
outside of the helmet, deforms and/or crushes the crushable foam or
other similar material making up outer layer 122, thereby absorbing
and releasing energy from the impact. For purposes of this
disclosure, "high velocity" impacts should be considered to
encompass those defined by the ASTM vertical drop specifications
for helmets and "low velocity" impacts should be considered those
at or less than one-half of those defined by the ASTM vertical drop
specifications for helmets, which may vary depending on the
intended use of the helmet. The middle layer 124 then isolates, or
at least reduces, the impact and energy transferred to the inner
layer 126. Middle layer 124 may also be configured to spread the
impact energy across a larger area of inner layer 126, thereby
resulting in significantly lower energy transfer to the head and
increased time of head deceleration.
[0029] Again, without being limited by theory, during relatively
low velocity impacts, inner layer 126 may compress as the head
pushes into the foam or other material making up inner layer 126,
thereby decelerating the head. The outer layer 122 may provide
limited, but important, energy absorption, and may spread the low
velocity impact across a larger area, thereby reducing its transfer
towards the head. The middle layer 124 may both isolate the
exterior impact from the inner layer 126 and isolate the interior
layer impact from the outer layer 122.
[0030] It is thought that the inventive structures disclosed herein
also provide improved protection from multiple, low velocity
impacts and improved durability resulting from such impacts. More
particularly, without being limited by theory, it appears that,
since the inner layer 126 primarily functions to decelerate the
head during such impacts (for embodiments in which the layered
protective structure comprises a helmet), the use of compressible,
resilient foam materials, or other materials with similar
properties, allows inner layer 126 to maintain its absorption
properties through repeated compressions and expansions while
conforming back to its original shape, thereby enhancing durability
as well as impact protection.
[0031] Through testing, it has been determined that the embodiments
and inventive concepts described herein significantly improve
g-force management (reduced g forces) from high velocity impacts
consistent with, for example, motorsports, as well as low velocity
impacts, relative to existing helmet technology. Additionally, the
embodiments and inventive concepts described herein may provide
improved g-force management and/or durability from repeated
impacts. These experimental results are summarized in the examples
listed below.
Example 1
[0032] Tests were performed on several currently available helmets
within the motorcycle, bike, snow sport, and skateboard industries
at specific speeds, drop heights and anvils. FIG. 4 is a graph
depicting the results of these experiments and comparing peak
g-forces for helmets at three different drop heights. The graph
compares the results of these tests for a helmet incorporating a
layered, inner shell according to one embodiment of the invention
disclosed herein compared with a best result from among a selection
of currently-available helmets from leading manufacturers, a worst
result from among such helmets, and an average result from among
such helmets.
[0033] The results indicate that the design described herein
results in significantly superior g force reduction compared to
currently available helmets. More particularly, as shown in FIG. 4,
at a first drop from about 50 cm (about 3.09 m/s impact speed), an
embodiment of the invention recorded a peak g-force of less than 50
(as shown at 402). A best result from among the other helmets is
shown at 404, a worst result from among the other helmets is shown
at 406, and the average result from among the other helmets is
shown at 408. As can be seen from comparing these results, an
embodiment of a helmet according to the invention achieved a result
in terms of g forces at 50 cm that is about half of most other
industry helmets.
Example 2
[0034] The results from a second test at a drop height of about 78
cm (about 3.89 m/s impact speed) are even more dramatic in
illustrating the improvements available from incorporating the
inventive concepts described herein into helmets and/or other
protective gear. As shown in FIG. 4, an embodiment of the invention
recorded a peak g force just over 50 (as shown at 412). A best
result from among the other helmets at 78 cm is shown at 414, a
worst result from among the other helmets is shown at 416, and the
average result is shown at 418. As can be seen from comparing these
results, an embodiment of a helmet according to the invention
achieved a result in terms of g forces at 78 cm substantially
better than the other helmets tested.
Example 3
[0035] The results from a third test at a drop height of about 160
cm (about 5.59 m/s impact speed) illustrate that the benefits from
incorporating the inventive concepts described herein into helmets
and/or other protective gear continue for high velocity impacts. As
again shown in FIG. 4, an embodiment of the invention recorded a
peak g-force of about 100 (as shown at 422). A best result from
among the other helmets at 160 cm is shown at 424, a worst result
from among the other helmets is shown at 426, and the average
result is shown at 428. As can be seen from comparing these
results, an embodiment of a helmet according to the invention
achieved a result in terms of g forces at a drop height of about
160 cm that is less than half of the average result from among the
other helmets, just over one-half of the best helmet, and about
two-fifths of the worst helmet.
[0036] As illustrated by each of the above-referenced examples,
helmets incorporating protective structures according to the
invention may achieve substantially-improved performance over
related helmets for all three impact velocities. In fact, as also
illustrated by each of these experimental working examples, helmets
incorporating protective structures according to the invention
experienced g-forces for each of the three drop heights that were
less than or equal to about 100 g's, which is currently considered
to be the desired threshold for concussion avoidance.
[0037] Despite this improved performance, some embodiments may be
configured to provide such protection with a smaller thickness than
most other protective structures. Indeed, in some embodiments, the
combined thickness of the three layers of the protective structure
may be less than about 30 mm. In some such embodiments, the
combined thickness of the three layers may be less than or equal to
about 24 mm. Indeed, the helmet used in the above-referenced test
results had a thickness of only about 24 mm, including the exterior
shell of the helmet, at its thickest point. The helmet used in this
testing comprised an outer layer of EPS foam having a thickness of
about 10 mm, a middle layer of ABS plastic having a thickness of
about 1 mm, and an inner layer of EVA foam having a thickness of
about 11 mm.
[0038] FIG. 5 is a graph depicting the g-forces associated with a
first impact at a height of about 20 inches on a helmet
incorporating a layered inner shell according to one embodiment of
the invention compared with other helmets at the same height not
incorporating the inventive subject matter disclosed herein. The
data depicted in FIG. 5 corresponds with and represent the same
experiment used to obtain the results depicted in the leftmost
portion of the bar graph of FIG. 4.
[0039] The g forces associated with the helmet incorporating a
layered inner shell according to one embodiment of the invention is
shown at line 502. Similarly, the g forces associated with two
other helmets (neither of which obtained the worst result shown in
FIG. 4) are shown at lines 504 and 506, respectively.
[0040] As shown in FIG. 5, the helmet incorporating a layered,
inner shell according to one embodiment of the invention exhibited
a g-force curve that indicates the ability to much more effectively
spread the forces due to helmet impact over time, and to lower the
peak forces experienced by a user/wearer of the helmet. More
particularly, the g-force curve at 502 is much more flat than
either of the other two curves and peaks at a number about half of
either of the other two curves.
[0041] FIG. 6 is a graph depicting the g-forces associated with a
second impact at the same site as the first impact referenced in
FIG. 5 at a height of about 31 inches on the helmet incorporating a
layered inner shell according to the embodiment of the invention
used in the experiment represented in the curve of FIG. 5 compared
with two other helmets also used to obtain the results illustrated
in FIG. 5.
[0042] The g forces associated with the helmet incorporating a
layered inner shell according to the embodiment of the invention
used in the experiment depicted in FIG. 5 is shown at line 602.
Similarly, the g forces associated with the two other helmets used
in the same experiment are shown at lines 604 and 606,
respectively.
[0043] As shown in FIG. 6, the helmet incorporating a layered inner
shell according to one embodiment of the invention exhibited a
g-force curve that further demonstrates the ability of this
protective structure to much more effectively spread the forces due
to helmet impact over time, and to lower the peak forces
experienced by a user/wearer of the helmet. More particularly, the
g-force curve at 602 is much more flat than either of the other two
curves and peaks at a number less than half of either of the other
two curves.
[0044] FIG. 7 is a graph depicting the g-forces associated with a
third impact at the same site as the first and second impacts
referenced in FIGS. 5 and 6 at a height of about 63 inches on the
helmet incorporating a layered inner shell according to the
embodiment of the invention used in the experiments represented in
the curves of FIGS. 5 and 6 compared with two other helmets also
used to obtain the results illustrated in FIGS. 5 and 6.
[0045] The g forces associated with the helmet incorporating a
layered inner shell according to the embodiment of the invention
used in the experiment depicted in FIG. 7 is shown at line 702.
Similarly, the g forces associated with the other two helmets used
in the same experiment are shown at lines 704 and 706,
respectively.
[0046] As shown in FIG. 7, the helmet incorporating a layered inner
shell according to one embodiment of the invention exhibited a
g-force curve that further demonstrates the ability of this
protective structure to much more effectively spread the forces due
to helmet impact over time, and to lower the peak forces
experienced by a user/wearer of the helmet. More particularly, the
g-force curve at 702 is much more flat than either of the other two
curves and peaks at a number well below either of the other two
curves.
[0047] It should be noted that, upon reviewing and comparing FIGS.
4-7, the embodiment of the invention used in the experiments
substantially outperformed the competition. This helmet was also
able to substantially reduce peak g-forces during all test
criteria, including high velocity impacts obtained at drop speeds
of about 5.6 m/s, which is the same velocity as the European
Committee for Standardization EN1077 standard, to less than or
equal to about 100 g's. This is important since this amount of
force has been considered an approximate threshold for avoiding
concussions. Thus, some embodiments of the invention may be able to
avoid even a concussion with respect to impacts that for many other
helmets would likely result in serious injury. Moreover, this
helmet was able to achieve such performance while also providing a
relatively small thickness profile (about 24 mm).
[0048] FIG. 8 depicts an embodiment of a middle layer 800
comprising a plurality of openings 802 configured to be used in a
layered protective structure. Each of the openings 802 is defined
by a plurality of crimped walls 804, which extend from a surface
806 of middle layer 800. In the depicted embodiment, each of the
various crimps/walls 804 extends from surface 806 at an angle of
about 45 degrees. However, it is contemplated that in alternative
embodiments, the walls defining openings 802 may extend from a
curved or flat surface defining a middle layer of a layered
protective structure at angles ranging from about 35 degrees to
about 90 degrees. It is also contemplated that in certain other
preferred embodiments, the walls defining openings 802 may extend
from a curved or flat surface defining a middle layer of a layered
protective structure at an angle of about 90 degrees.
[0049] The openings 802 may correspond with vent openings in the
outer shell of, for example, a helmet. However, in addition to
serving this venting purpose, providing a crimp on a middle layer
of a layered protective structure may serve to improve the function
of the protective structure. As such, it is contemplated that, in
some embodiments, such a middle layer may comprise one or more
crimped walls even if such walls do not necessarily define an
opening in the middle layer. In other words, in some embodiments,
one or more crimps or similar structures may be provided to
increase rigidity or otherwise improve the function of a layered
protective structure, such as by improving the ability of the
middle layer to spread forces between one or more inner and/or
outer layers, irrespective of whether such structures also define
openings, such as vent openings.
[0050] FIG. 9 depicts another embodiment of a middle layer 900
usable with certain embodiments of layered protective structures.
Middle layer 900 comprises a plurality of openings 902 defined by
crimped walls 904. Each of the openings 902 is defined by a
plurality of crimped walls 904 that extend from a surface 906 of
middle layer 900. In the depicted embodiment, each of the various
crimps/walls 904 extends from surface 906 at an angle of about 45
degrees. However, it is contemplated that in alternative
embodiments, the walls defining openings 902 may extend from a
curved or flat surface defining a middle layer of a layered
protective structure at angles ranging from about 35 degrees to
about 90 degrees.
[0051] As depicted in FIG. 9, openings 902 are also arranged in a
honeycomb fashion adjacent to one another. In other words, each of
openings 902 forms a hexagonal shape and each opening 902 (other
than those positioned at a periphery of the honeycomb structure) is
positioned adjacent to six other such openings 902 to form a
honeycomb structure. However, other embodiments are contemplated in
which openings 902 are formed from other polygonal or non-polygonal
shapes.
[0052] Openings 902 may, in some embodiments, may be aligned with
vent openings in the outer shell of, for example, a helmet. As
mentioned above, the raised/crimped structures surrounding openings
902 may be provided to increase rigidity or otherwise improve the
function of a layered protective structure, such as by improving
the ability of the middle layer to spread forces between one or
more inner and/or outer layers.
[0053] Middle layer 900 also comprises a second honeycomb structure
comprising non-crimped openings 910. Openings 910 may, like
openings 902, be formed as hexagons or other polygons and may be
arranged such that each side of the polygonal opening is positioned
adjacent to a corresponding side of an adjacent polygonal opening
910.
[0054] Additional tests were performed using embodiments described
herein, the results of which further establish significant
improvement relative to existing helmet technology. These further
experimental results are summarized in the additional examples
listed below.
Example 4
[0055] Tests were performed on several currently available helmets
at specific drop heights to assess peak linear acceleration, peak
angular acceleration, and Head Injury Criterion ("HIC"), which is a
commonly-used measure of the likelihood of head injury resulting
from an impact with a helmet. Table 1 below summarizes the results
of these experiments at a drop height of 51 cm.
TABLE-US-00001 TABLE 1 Linear (g) Rotational (krad/s/s) HIC Base
63.9 3.5 105.9 MIPS 62.8 2.6 117.2 Embodiment 43.8 3.5 55.0
[0056] The table above compares the results of tests at a drop
height of 51 cm for a helmet incorporating a layered, inner shell
according to one embodiment of the invention disclosed herein
("Embodiment") compared with those from a typical, off-the-shelf
helmet ("Base") and those from a particular, high-end brand of
helmet (MIPS).
[0057] Table 2 below summarizes the results of these experiments at
a drop height of 77 cm.
TABLE-US-00002 TABLE 2 Linear (g) Rotational (krad/s/s) HIC Base
83.4 6.5 183.1 MIPS 91.5 3.9 242.6 Embodiment 56.2 4.7 96.3
[0058] Table 3 below summarizes the results of these experiments at
a drop height of 206 cm.
TABLE-US-00003 TABLE 3 Linear (g) Rotational (krad/s/s) HIC Base
151.5 6.6 886 MIPS 146.3 5.1 783 Embodiment 114.7 4.6 572
[0059] These results indicate that the design described herein
results in significantly better HIC scores, which translate to
fewer and less severe injuries.
[0060] The foregoing specification has been described with
reference to various embodiments. However, one of ordinary skill in
the art will appreciate that various modifications and changes can
be made without departing from the scope of the present disclosure.
Accordingly, this disclosure is to be regarded in an illustrative
rather than a restrictive sense, and all such modifications are
intended to be included within the scope thereof. Likewise,
benefits, other advantages, and solutions to problems have been
described above with regard to various embodiments. However,
benefits, advantages, solutions to problems, and any element(s)
that may cause any benefit, advantage, or solution to occur or
become more pronounced are not to be construed as a critical, a
required, or an essential feature or element. The scope of the
present invention should, therefore, be determined only by the
following claims.
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