U.S. patent application number 14/886505 was filed with the patent office on 2017-03-09 for sports helmet with collapsible modular elements.
The applicant listed for this patent is Vyatek Sports, Inc.. Invention is credited to Howard Alvin Lindsay.
Application Number | 20170065018 14/886505 |
Document ID | / |
Family ID | 58189232 |
Filed Date | 2017-03-09 |
United States Patent
Application |
20170065018 |
Kind Code |
A1 |
Lindsay; Howard Alvin |
March 9, 2017 |
SPORTS HELMET WITH COLLAPSIBLE MODULAR ELEMENTS
Abstract
The present disclosure provides a helmet for a user's head,
comprising a shell configured to at least partially surrounds the
user's head, an energy-absorbing layer, and a plurality of
collapsible modular elements that are individually removably
attached to and detached from the helmet. Collapsible modular
elements, as used herein, are elements attached to the helmet that
collapse or otherwise crush and permanently deform or to
temporarily deform upon receiving an impact force of a particular
pre-determined amount. By collapsing, energy from the impact is
more effectively absorbed instead of being transferred to the user
of the helmet.
Inventors: |
Lindsay; Howard Alvin;
(Fountain Hills, AZ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Vyatek Sports, Inc. |
Fountain Hills |
AZ |
US |
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|
Family ID: |
58189232 |
Appl. No.: |
14/886505 |
Filed: |
October 19, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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13524597 |
Jun 15, 2012 |
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14886505 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A42B 3/20 20130101; A42B
3/067 20130101; A42B 3/063 20130101; A42B 3/065 20130101 |
International
Class: |
A42B 3/06 20060101
A42B003/06; A42B 3/20 20060101 A42B003/20; A42B 3/12 20060101
A42B003/12 |
Claims
1. A helmet for a user's head, comprising: a shell configured to at
least partially surrounds the user's head, an energy-absorbing
layer, a plurality of collapsible modular elements, wherein the
collapsible modular elements are each individually removably
attached to and detached from the helmet.
2. A helmet according to claim 1, wherein the collapsible modular
elements are adhered to an outer surface of the shell.
3. A helmet according to claim 1, further comprising a compliant
layer, and wherein the collapsible modular elements are adhered to
an outer surface of the compliant layer.
4. A helmet according to claim 1, wherein the shell has a plurality
of apertures for receiving and releasably holding the collapsible
modular elements.
5. A helmet according to claim 4, wherein the collapsible modular
elements further comprise a neck for engaging the shell and
attaching the collapsible modular elements to the shell.
6. A helmet according to claim 1, wherein at least one of the
collapsible modular elements is comprised of a thin wall surface
surrounding a volume.
7. A helmet according to claim 6, wherein the volume is empty.
8. A helmet according to claim 6, wherein the volume is at least
partially filled with a first energy absorption material.
9. A helmet according to claim 8, wherein the volume is at least
partially filled with a second energy absorption material.
10. A helmet according to claim 9, wherein the first and second
energy absorption materials are layered.
11. A helmet according to claim 1, the collapsible modular elements
create a stand-off height relative to the helmet.
12. A helmet according to claim 11, the collapsible modular
elements absorb energy in a region between the shell and the
stand-off height.
13. A helmet according to claim 1, further comprising at least one
of a contiguous layer of foam and air pads on an inner surface of
the shell.
14. A helmet for a user's head, comprising: a compliant layer
configured to at least partially surrounds the user's head, a
plurality of collapsible modular elements, wherein the collapsible
modular elements are each individually removably attached to and
detached from the compliant layer.
15. A helmet according to claim 14, wherein at least one of the
collapsible modular elements is comprised of a thin wall surface
surrounding a volume.
16. A helmet according to claim 15, wherein the volume is
empty.
17. A helmet according to claim 15, wherein the volume is at least
partially filled with a first energy absorption material.
18. A helmet according to claim 17, wherein the volume is at least
partially filled with a second energy absorption material.
19. A helmet according to claim 18, wherein the first and second
energy absorption materials are layered.
20. A helmet according to claim 14, the collapsible modular
elements create a stand-off height relative to the helmet and the
collapsible modular elements absorb energy in a region between the
compliant layer and the stand-off height.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part patent
application of U.S. application Ser. No. 13/524,597 entitled
"Modular Sports Helmet," filed on Jun. 15, 2012, which is
incorporated herein by reference.
FIELD OF INVENTION
[0002] This invention relates generally to a high-performance
helmet incorporating a collapsible modular design to achieve, among
other things, improvements in energy absorption and cost
efficiencies. The characteristics of the disclosure may be
particularly useful in high-impact sports such as football,
lacrosse, hockey, baseball, softball, cycling, skating, skiing,
polo, and the like, as well as other non-sports applications where
protection of a user is important.
BACKGROUND OF THE INVENTION
[0003] Many current helmet designs are essentially plastic, formed
shells with some variation of energy-absorbing material, such as
foams, air pads, or a combination of both, placed inside or
external to the shell.
[0004] To optimize performance, many helmet designs attempt to
balance competing functional features against an overall challenge
of cost containment. In this regard, attempts are made to design
helmets that not only sustain the required impacts of their
specific sport, but to provide adequate ventilation, to be capable
of periodic repainting or refinishing, and frequently, to
accommodate or support a separate face mask. Attempts to
incorporate other criteria such as weight, stand-off distance from
the user head contours ("helmet profile"), and overall comfort have
been made as well. However, such attempts create compromises where
certain features dominate the design, and the other criteria are
reduced to various degrees.
[0005] For example, conventional football helmets are designed to
protect players from catastrophic brain injuries caused by severe
impacts and to function effectively with multiple impacts without
cracking. This leads to designs where typically less than 20% of
the total helmet mass is related to energy absorption, and thus,
over 80% of the helmet mass behaves more like a spring, which
effectively transfers the energy instead of absorbing it.
[0006] Moreover, many helmet designs are based on a common design
element such as the molded plastic shell. The helmets outer shell
is designed to be capable of being refinished several times during
its useful life, but if a key element is damaged during use, and
thus not functional, the helmet has to be replaced in whole.
Replacement may be necessary due to damage, old age, or to having
been refinished too many times. In any event, this type of helmet
is designed take multiple hits without failure, to last a long
time, and to be refinished for cosmetic purposes.
[0007] Another class of helmets are designed to fail strategically
during a severe impact, essentially giving up their structure
during the event and thus absorbing the energy of the impact
through the strategic "failure" of the material. For example,
bicycle helmets fall within this category. They are designed to be
discarded after a severe crash, as the structural foams that the
helmets are made of "crush" and absorb the energy of a severe
impact. The designs are very efficient at absorbing energy, however
they are not designed to withstand multiple impacts.
[0008] Multi-hit helmet designs can often be described as having
two-stage energy absorption. In this respect, a hard, outer shell
helps distribute the impact load ("Stage 1") and the materials
inside to the helmet handle the majority of the "absorption" of the
impact loads ("Stage 2").
[0009] Due to the needs of creating a shell that is tough, durable,
long-lasting, well-ventilated, low-profile, lightweight, and
capable of handling multiple impacts, of being refinished, and of
functioning in high and low temperatures, many helmets are
constructed with polycarbonate or ABS plastic molded shells that
are thick and rigid.
[0010] These thick, rigid shells do not dissipate much energy
during an impact, and as such, transfer much of it to the
absorption materials inside the helmet. Therefore, Stage 1 of the
energy absorption mechanism is largely ineffective, and the bulk of
energy absorption is accomplished by the Stage 2 design elements,
namely foams and air pads inside the hard shell. However, these
Stage 2 elements generally function in an elastic or slightly
visco-elastic manner, and with reference to FIGS. 13 and 14, they
are at best moderately effective for absorbing energy.
[0011] Moreover, they tend to have design elements that are
designed for comfort, which allow them to also work under low
impact loads, or design elements that are intended to work under
high impact loads However, these Stage 2 design elements do not
function well for both high and low impact loads. This type of
multi-hit helmet designed is intended to work under severe (high)
impact loads and to be less effective (with regard to energy
absorption) when subjected to moderate or low impact loads. Under
those conditions, the helmet effectively passes most of the load
(and energy) to the player wearing it.
[0012] Thus, technology that incorporates more energy absorption
strategies is desirable because it can potentially decrease the
incidence of athlete injury caused by traumatic head injuries,
concussions, or repetitive head trauma. Additionally, technology
that can realize different properties of different materials is
desirable. Further, technology that allows partial replacement of
helmet components is desirable because it may decrease the cost of
helmet refurbishment and replacement.
SUMMARY OF THE INVENTION
[0013] While the ways in which the present disclosure addresses the
disadvantages of the prior art will be discussed in greater detail
below, in general, the present disclosure provides a helmet for a
user's head, comprising a shell, which may be rigid or compliant,
configured to at least partially surround the user's head,
optionally, an energy-absorbing layer, and one or more collapsible
modular elements that are individually removably attached to the
helmet. Collapsible modular elements, as used herein, are elements
(that typically respond in an in-elastic, or highly visco-elastic,
manner) attached to the helmet that collapse or otherwise crush and
permanently deform or to temporarily deform upon receiving an
impact force of a particular pre-determined amount. By collapsing,
as illustrated in FIG. 15, the energy from the impact is more
effectively absorbed instead of being transferred to the user of
the helmet.
[0014] For example, the collapsible modular elements may be
comprised of a thin wall surface surrounding an empty volume. The
collapsible modular element collapses into the empty volume at a
particular impact force. Alternatively, the volume may be filled
with one or more energy absorption materials (first, second, etc.),
optionally, in one or more layers.
[0015] In this regard, the collapsible modular elements may be
"tuned" so as to have different regions that collapse at different
impact forces, so as to provide more than one impact absorption
capability (e.g., higher vs. lower impact forces). For example, the
thin wall material thickness may vary so that different portions of
the collapsible modular elements collapse at different impact
forces. Similarly, by choosing multiple materials to fill the
volume, varying impact energy absorption may be accomplished.
[0016] The collapsible modular elements can be adhered to an outer
surface of the shell, such as "hard or rigid" shells used in
conventional plastic helmets or to "soft or compliant" shells used
in new helmet designs. Alternatively, the shell or compliant layer
sections may have one or more apertures for receiving, attachment
and releasably holding the collapsible modular elements or
providing ventilation. These apertures can be an effective
attachment option as well as a way to add additional energy
absorption, while minimizing the weight added to the helmet.
[0017] A thin wall surface of a collapsible modular element can be
configured with a depression to engage the shell proximate a
corresponding aperture for receiving and releasably holding the
collapsible modular elements in the aperture.
[0018] The collapsible modular elements can create a variable
stand-off height relative to the helmet, so that the collapsible
modular elements absorb energy in a region between the shell and
the stand-off height. A higher stand-off height will generally
improve energy absorption while a lower stand-off height will have
less resistance from users who seek to minimize the overall outer
helmet profile.
[0019] The collapsible modular elements may thus provide additional
stages of impact energy absorption and may be adapted to optimize
performance for a specific sport or function by varying
characteristics such as size, location, weight, material, method of
attachment, and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1a is a side view of a modular football helmet in
accordance with an exemplary embodiment of the present
disclosure.
[0021] FIG. 1b is a perspective view of a modular football helmet
in accordance with an exemplary embodiment of the present
disclosure and illustrating the removable panels when released from
the apertures.
[0022] FIG. 2 is a close-up cross-sectional view of a helmet with a
depression and aperture, and a modular panel attached to the helmet
in accordance with an embodiment of the present disclosure.
[0023] FIG. 3 is a cross-sectional view of a helmet with a
depression, a modular panel, and an attachment mechanism, in
accordance with an embodiment of the present disclosure.
[0024] FIG. 4 is a close-up cross-sectional view of a helmet shell
with an aperture, a modular panel, and an attachment mechanism
located on the perimeter edge of the panel and aperture in
accordance with an embodiment of the present disclosure.
[0025] FIG. 5 is a close-up cross-sectional view of a helmet shell
with an aperture and a depression, a modular panel, and an
attachment mechanism located in the depression in accordance with
an embodiment of the present disclosure.
[0026] FIG. 6a is a rear view of a football helmet with apertures
for removably receiving collapsible modular elements in accordance
with an embodiment of the present disclosure.
[0027] FIG. 6b is a side view of a football helmet with apertures
for removably receiving collapsible modular elements in accordance
with an embodiment of the present disclosure.
[0028] FIG. 7 is a partial perspective view of a football helmet
with apertures for removably receiving collapsible modular elements
showing the collapsible modular elements in some of the apertures
in accordance with an embodiment of the present disclosure.
[0029] FIG. 8a is a side view of a collapsible modular element in
accordance with an embodiment of the present disclosure.
[0030] FIG. 8b is a cross-sectional side view of a collapsible
modular element in accordance with an embodiment of the present
disclosure.
[0031] FIG. 8c is a perspective view of a collapsible modular
element in accordance with an embodiment of the present
disclosure.
[0032] FIG. 9 is a cross-sectional side view of a collapsible
modular element with layers of energy absorbing materials shown
therein in accordance with an embodiment of the present
disclosure.
[0033] FIG. 10a is a cross-sectional side view of two collapsible
modular elements inserted in corresponding apertures in a shell of
a helmet in accordance with an embodiment of the present
disclosure.
[0034] FIG. 10b is a cross-sectional side view of two collapsible
modular elements adhered to the shell of a helmet in accordance
with an embodiment of the present disclosure.
[0035] FIG. 11a is a cross-sectional side view of a collapsible
modular element adhered to the surface of a shell of a helmet in
accordance with an embodiment of the present disclosure.
[0036] FIG. 11b is a cross-sectional side view of a collapsible
modular element adhered to the surface of a compliant layer of a
helmet in accordance with an embodiment of the present
disclosure.
[0037] FIG. 12 is a cross-sectional side view of a collapsible
modular element adhered to a compliant layer on the surface of a
shell of a helmet in accordance with an embodiment of the present
disclosure.
[0038] FIG. 13 is a graph illustrating a stress-strain curve of an
elastic material.
[0039] FIG. 14 is a graph illustrating a stress-strain curve of a
visco-elastic material.
[0040] FIG. 15 is a graph illustrating a stress-strain curve of an
in-elastic material.
DETAILED DESCRIPTION
[0041] The following description is of an exemplary embodiment of
the invention only, and is not intended to limit the scope,
applicability, or configuration of the disclosure in any way.
Rather, the following description is intended to provide a
convenient illustration for implementing various embodiments of the
disclosure. As will become apparent, various changes may be made in
the function and arrangement of the elements described in these
embodiments without departing from the scope of the disclosure as
set forth in the claims.
[0042] For example, in the context of the present disclosure, the
apparatus hereof finds particular use in connection with sports
helmets such as football helmets, baseball helmets, hockey helmets,
and the like. Additionally, the specific characteristics of each
embodiment of the present disclosure are adapted to be optimized
for performance in a particular sport. However, generally speaking,
numerous applications of the present disclosure may be
realized.
[0043] For example, although sports helmets are primarily used in
conjunction with participation in an athletic activity, their
general purpose is to protect the user's head from impact related
trauma. Accordingly, as used herein, the term "helmet" means any
head-protective apparatus which at least partially surrounds the
user's head. Briefly, by way of non-limiting example, other helmets
for motorcycle, automobile, recreational vehicles, military and the
like, as well as other protective gear, such as elbow pads, knee
pads, thigh pads, shin guards, shoulder pads, chest and back
protectors and the like, may likewise benefit from the present
disclosure, and use of the term "helmet" is not intended to limit
the scope, applicability, or configuration of the disclosure in any
way.
[0044] Likewise, numerous materials may be used to achieve each
element of the apparatus disclosed herein. Generally speaking,
elements of the disclosure may be made of various materials and
composites, including polyethylene, polycarbonate plastic, ABS
plastic, carbon fiber, metals, ceramics, polystyrene foam, vinyl
nitrile foam, and thermoplastic urethane foam. That being said,
although an exhaustive list of materials is not included herein,
one skilled in the relevant art will appreciate that various
conventional plastics and energy-absorbing materials may be used,
all of which fall within the scope of the present disclosure.
[0045] Additionally, various materials may be combined to obtain
the most attractive characteristics of existing (or as yet unknown)
plastics, energy-absorbing materials, and composite materials, and
may be incorporated into the helmet elements disclosed herein,
whose combined performance characteristics may potentially increase
impact energy absorption or cost efficiency.
[0046] As noted above, in conventional sports helmets, impact
energy is dissipated in two stages, as accomplished by a hard,
outer shell and an inner, energy-absorbing layer. In accordance
with the present disclosure, additional stages of impact energy
absorption can be achieved through incorporation of collapsible
modular design elements.
[0047] For example, a helmet may be improved with the addition of
various modular elements, such as collapsible modular elements,
panels, face masks, or the like, releasably attached to a shell,
which surrounds a conventional, energy-absorbing layer. As used
herein, "collapsible modular elements" means generally in-elastic
elements (though highly visco-elastic and elastic materials may
also fall within the scope of the present disclosure) that collapse
or otherwise crush and permanently deform or to temporarily deform
upon receiving an impact force of a particular pre-determined
amount, and by collapsing, energy from the impact force is more
effectively absorbed instead of being transferred elsewhere, such
as to or through the shell and other components of the helmet to
the user of the helmet.
[0048] For example, FIG. 14 illustrates a stress-strain curve
showing the improved energy absorption of this type of
visco-elastic materials. The energy absorbed is defined as the
integration of the area under the stress/strain curve. It can also
be described by a material that has a large hysteresis loop, which
generally refers to materials that have a loss in their response to
stress by not returning in a linear manner from a strain
standpoint. Another way to describe it as material that has a
permanent "set" when loaded.
[0049] Thus, the collapsible modular elements can provide
additional energy absorption by intentional deformation or release,
thereby potentially decreasing the incidence of injury.
Additionally, collapsible modular elements may be optionally
removed and replaced after severe impacts, permanent deformation,
ordinary wear and tear, or for any other reason. Collapsible
modular design may improve cost efficiencies by decreasing the cost
of helmet refurbishment and the frequency of helmet
replacement.
[0050] Additionally, the mechanism attaching various modular
elements to the helmet may itself provide further stages of impact
energy absorption. High-strain rate-sensitive materials can help
"tune" the level of energy (e.g., increase or decrease the amount
of energy) required to remove a modular element. As such, the
attachment mechanism may be made of various materials to meet the
particular requirements of a specific sport, as determined by the
types of impact the helmet is likely to receive. For example, a
modular element that is separated from a rigid outer shell by an
attachment mechanism made of a high-strain, moderate stiffness
material may provide improved energy absorption for high load,
short duration impacts.
[0051] For example, a baseball batter's helmet may have panels or
collapsible modular elements that permanently deform, thereby
converting the kinetic impact energy of the ball to strain energy
in the panel or collapsible modular element upon an impact such as
that caused by a fastball pitch. Deformed panels/collapsible
modular elements may be removed from the helmet and replaced.
Alternatively, energy from a fastball pitch may be dissipated when
the ball strikes a rigid panel/collapsible modular elements, and an
attachment mechanism made of moderate stiffness material designedly
releases the panel/collapsible modular elements from the
helmet.
[0052] The above being noted, in accordance with an embodiment of
the present disclosure, a helmet comprises a shell, an
energy-absorbing layer, and at least one energy-absorbing panel
and/or a collapsible modular element, which is removably attached
to the helmet. In embodiments with panels, the panels themselves
may be made of a plurality of collapsible elements. Briefly, these
features of the present disclosure are provided in order that the
detailed description herein will be better understood and
appreciated; however, the present disclosure can also comprise
additional features, which will be subsequently described
herein.
[0053] For example, with reference to FIGS. 1a and 1b, 6a and 6b,
and 7, a helmet 100 comprises a shell 101, which may be adapted to
absorb impact energy. The shell 101 at least partially surrounds
the user's head and provides the structural base of the helmet 100.
The shell 101 may be hard and rigid, and its outer surface may be
adapted to be painted, resurfaced, or refinished, potentially to
accommodate graphic elements.
[0054] In various embodiments, the shell 101 may be made with
materials such as ABS plastic, polycarbonate plastic, or the like.
However, the shell 101 may be made of any number of plastics,
energy-absorbing materials, or composite materials. Further, the
shell's physical characteristics, such as flexibility, hardness,
weight, and shape, may be varied in any way necessary to accomplish
the desired performance characteristics while still falling within
the scope of the present disclosure.
[0055] In an exemplary embodiment of the present disclosure, and
with reference to FIGS. 1a and 1b, 6a and 6b, and 7 the shell 101
is shaped like a conventional football helmet and is located on the
exterior of the helmet 100, typically contiguous with an inner,
energy-absorbing layer 104. However, the shell 101 may be shaped to
accommodate the needs of any particular sport, or more generally,
in any way that at least partially surrounds the user's head.
Further, the shell 101 need not constitute the outermost layer of
the helmet 100, but may be located anywhere to accomplish energy
absorption.
[0056] The layer 104 may be adapted to further absorb energy. The
layer 104 may be more energy-absorbent than the shell 101, and may
be comprised of foam lining, foam pads, air pads, or any
combination thereof. That being said, the layer 104 may be
comprised of any apparatus that effectively absorbs impact energy
and generally cushions the user's head.
[0057] Foam lining and foam pads generally may be made of
polystyrene foam, vinyl nitrile foam, or thermoplastic urethane
foam. Air pads generally may comprise bladders adapted to be filled
with air and may be made of vinyl or a similarly flexible plastic
material. That being said, the layer 104 may be made of any
material that is sufficiently adapted to absorb impact energy.
[0058] The layer 104 may be located inside the shell 101, and may
be contiguous with the inner surface of the shell 101. In
embodiments comprising foam pads or air pads, the pads may be
placed strategically inside the helmet 100 to meet the specific
requirements of a particular sport, or to optimize characteristics
such as energy absorption, user comfort, and helmet profile. That
being said, the layer 104 need not be contiguous with the shell
101, and other elements may be interposed between the shell 101 and
the layer 104.
[0059] In accordance with the present disclosure, still further
energy absorption may be accomplished by modular elements.
[0060] For example, one or more panels or collapsible modular
elements may be releasably attached to the helmet, potentially
providing more effective energy absorption than the hard, outer
shell of conventional helmets. Accordingly, improved energy
absorption may increase the helmet's ability to prevent injury.
Further, the optional ability to remove and replace panels or other
collapsible modular elements may improve cost efficiencies by
decreasing the cost of helmet refurbishment and the frequency of
helmet replacement.
[0061] Panels may be intentionally collapsible as a means of
achieving improved energy absorption and of providing a visual
indicator of impact. Collapsible panels may be designed to
permanently deform upon severe impact or to temporarily deform.
Alternatively or in conjunction with deformation, the panels may
achieve improved energy absorption by intentionally detaching from
the helmet upon impact, thereby dissipating impact energy as strain
energy.
[0062] That being said, although an exhaustive list of means for
absorbing or dissipating energy is not included herein, one skilled
in the relevant art will appreciate that various means may be used,
all of which fall within the scope of the present disclosure.
[0063] Panels may be made of various materials or composites,
including polycarbonate plastic, ABS plastic, carbon fiber, metals,
ceramics, and the like. Different properties and their concomitant
benefits may be realized through use of materials that vary in
stiffness, strength, weight, flexibility, hardness,
energy-absorption ability, cost, or any other characteristic. That
being said, although an exhaustive list of materials is not
included herein, one skilled in the relevant art will appreciate
that various conventional plastics and energy-absorbing materials
may be used, all of which fall within the scope of the present
disclosure.
[0064] Panels may be strategically located on the helmet to
increase energy absorption. Panels may be located on the exterior
of the shell, may be interposed between the shell and the layer, or
may be located on the inner surface of the layer. Additionally,
panels may be located strategically to meet the specific
requirements of a particular sport.
[0065] For example, in the present exemplary embodiment, a football
helmet, panels 103 may be located on portions of the helmet 100,
such as the anterior, posterior, and lateral faces, which are
likely to receive impacts as a result of tackling. In one alternate
embodiment, a baseball batter's helmet, panels may be located on
portions of the helmet, such as the posterior and lateral faces,
which are likely to receive impacts as a result of pitching. That
being said, those skilled in the relevant art will appreciated that
the panels' location may vary depending on the particular
requirements of each helmet, and the embodiments described herein
is not intended to limit the scope of the present disclosure.
[0066] Additionally, the shell may comprise depressions or
apertures, and panels may be located therein. Apertures and
depressions may decrease the helmet's weight, may optimize
performance, may be an element of aesthetic design, may accommodate
collapsible modular elements of the helmet, or may be adapted for
any other function.
[0067] For example, a shell may be shaped like a conventional
bicycle helmet, comprising multiple apertures of varied size and
shape, designed to decrease helmet weight and increase aerodynamic
performance. Alternatively, a shell may be comprised of multiple
depressions to decrease helmet profile, thereby increasing
aesthetic quality and self-recognition, as measured by the user's
ability to pass a mirror test. In the exemplary embodiment of the
present disclosure, the shell 101 comprises six apertures 105, each
adapted to releasably hold an energy-absorbing panel 103, or
alternatively, a plurality of collapsible modular elements.
[0068] With reference now to FIG. 4, a panel 103 may be located in
an aperture 105 of the shell 101. In another embodiment and with
reference to FIG. 3, a panel 103 may be located in a depression 108
of the shell 101. In yet another embodiment and with reference to
FIG. 5, a panel 103 may be located in both a depression 108 and an
aperture 105 of the shell 101, such that the aperture 105 is formed
at the bottom of the depression 108 and is adapted to releasably
hold the panel 103 in place.
[0069] That being said, a panel need not be located in a depression
or aperture, and the size, shape, and number of apertures or
depressions may vary depending on the particular helmet
characteristics desired, or the specific requirements of a
particular sport. Additionally, and in accordance with the present
disclosure, the shell may or may not comprise apertures, and it may
or may not comprise depressions.
[0070] Further, a panel which is located in a depression or
aperture may or may not have the same three-dimensional profile as
the depression or aperture. However, panels sharing the
three-dimensional profile of a depression can potentially decrease
the helmet profile and create a continuous outer surface of the
helmet that is aesthetically pleasing.
[0071] With reference to FIG. 2, a panel 103 may be located in a
depression 108 formed in the shell 101 partially surrounding the
user's head 107, such that the distance from the outer surface of
the panel 103 to the inner surface of the attachment mechanism 109
is approximately equivalent to the depth of the depression 108. In
another embodiment and with reference to FIG. 4, a panel 103 that
sits in an aperture 105 may share substantially the same surface
profile as the aperture 105 in which it fits, so as to minimize
helmet profile and create a continuous outer surface of the helmet
that is aesthetically pleasing.
[0072] That being said, the depth, orientation, and profile of a
panel located in either a depression or an aperture may vary. In
the present exemplary embodiment, a helmet 100 comprises panels
103, which are located in apertures 105 of approximately equivalent
orientation and profile. However, apertures, depressions, and
panels may take any number of sizes, shapes, and configurations,
and the exemplary embodiment described herein is not intended to
limit the scope of the present disclosure. As will be appreciated,
the specific requirements of a particular sport may require panels
of varying depth, profile, and orientation for optimal energy
absorption.
[0073] Panels themselves may additionally comprise one or more
vents of varying size and shape. Panel vents may function to
increase ventilation and airflow, thereby improving user comfort.
Panel vents may also increase energy absorption, increase
aerodynamic performance, increase aesthetic appeal, or decrease
weight, among other things. In the present exemplary embodiment, a
helmet 100 comprises panels 103 with panel vents 106 which are
generally oval in shape and are orientated parallel to one another.
That being said, panel vents may take any number of sizes, shapes,
and orientations, and the exemplary embodiment described herein is
not intended to limit the scope of the present disclosure.
[0074] Panels may be releasably attached to the helmet to
accomplish any of several functions. For example, releasable
attachment improve energy absorption; it may allow panel
replacement in the event of deformation after impact; it may allow
panel reattachment in the event of intentional detachment after
impact; and it may allow panel replacement in the event of helmet
damage, regular wear and tear, or for any other reason.
Accordingly, improved energy absorption may increase the helmet's
ability to prevent injury. Further, the optional ability to remove
and replace panels may improve cost efficiencies by decreasing the
cost of helmet refurbishment and the frequency of helmet
replacement
[0075] With reference to FIG. 2, a panel 103 may be releasably
attached to the shell 101 by a panel attachment mechanism 109. The
attachment mechanism 109 may be made of various high-strain,
rate-sensitive materials which increase energy absorption through
planned failure at specific loads, as determined by the types of
impact the helmet is likely to receive.
[0076] The panel attachment mechanism 109 can be adapted to hold a
panel 103 securely in place on the shell 101, but to intentionally
release the panel 103 with application of sufficient force, and
thereafter, to optionally receive a panel, again holding it in
place. Further, the panel attachment mechanism 109 may be adapted
to join a panel with the shell interior, the shell exterior 101, a
shell depression 108, a shell aperture 105, the layer 104, or any
other locus on the helmet.
[0077] Additionally, the panel attachment mechanism may comprise
channel supports adapted to attach a panel to the helmet. The
channel support members may be semi-rigid and adapted to interlock
with one another upon application of sufficient force. The channel
support members are further adapted to release upon subsequent
applications of sufficient impact force.
[0078] In one embodiment and with reference to FIG. 3, two channel
support members 110, 111 can be respectively located in a
depression 108 on the exterior surface of the shell 101 and on the
proximal surface of a panel 103. In another embodiment and with
reference to FIG. 4, channel supports 112 may be located on the
perimeter edges of a panel 103 and a shell aperture 105,
respectively.
[0079] In other embodiments, the panel attachment mechanism may
include a slide-locking mechanism, a hook and slot mechanism, a
magnetic mechanism, an adhesive, or the like. It will be
appreciated that, although an exhaustive list is not included
herein, one skilled in the relevant art will appreciate that
various attachment mechanisms may be used, all of which fall within
the scope of the present disclosure.
[0080] In accordance with the present disclosure, still further
energy absorption may be accomplished by providing a plurality of
collapsible modular elements. For example, with reference to FIGS.
6a, 6b and 7, one or more collapsible modular elements 120 may be
releasably attached to the helmet, potentially providing more
effective energy absorption than the hard, outer shell of
conventional helmets. Further, the optional ability to remove and
replace collapsible modular elements 120 can create a new type of
helmet that has the high efficiency energy absorption capability of
"throw away" helmets (like bicycle helmets) while retaining
multi-hit capability, while also improving the cost efficiencies by
decreasing the cost of helmet refurbishment and the frequency of
helmet replacement.
[0081] Additionally, as described in more detail below, in
embodiments having apertures in the shell 101 for receiving
collapsible modular elements, material is removed from shell 101,
decreasing the mass of the shell 101. A 1 to 2 inch circle of a
typical football helmet shell typically weights between 5-10 grams,
while a thin walled collapsible modular element weighs less than
that, even when filled with additional energy absorbing materials
as described herein, resulting in improvements in overall
weight.
[0082] Collapsible modular elements 120 may be intentionally
collapsible as a means of achieving improved energy absorption and
of providing a visual indicator of a severe impact. Collapsible
modular elements 120 may be designed to permanently deform upon
severe impact or to temporarily deform and return to their normal
shape. Alternatively or in conjunction with deformation, the
collapsible modular elements 120 may achieve improved energy
absorption by intentionally detaching from the helmet 100 upon
impact, thereby dissipating some of the impact energy as strain
energy in "tearing loose" the connection.
[0083] As described in more detail below, the collapsible modular
elements 120 can be adhered to an outer surface of the shell itself
or to a compliant layer. Alternatively, the shell may have a
plurality of apertures for receiving and releasably holding the
collapsible modular elements.
[0084] With reference now to FIGS. 8a, 8b, 8c, 9, 10a, 11a and 11b
an exemplary collapsible modular element 120 is shown. The
illustrated collapsible modular element 120 is a thin walled
structure of a suitable inelastic, elastic, or visco-elastic walls
122 that is collapsible. For example, now known or as yet unknown
polymers, may be suitable. In the noted Figs., collapsible modular
element 120 is generally "puck shaped" with a generally elliptical
(here, circular) shape, though other shapes may also be used. For
example, with brief reference back to FIG. 7, collapsible modular
element 120 is hexagonal. However, it should be appreciated that
any number of shapes, symmetrical or asymmetrical, may be used and
fall within the scope of the present disclosure. For example,
squares, triangles, octagons and the like, as well as oblong and
irregular shapes may be substituted.
[0085] One benefit of the ability to choose various shapes is the
ability of the collapsible modular elements 120 to nest together to
create a reasonably "smooth" outer surface. For example, the
individual hexagonal collapsible modular elements 120 in FIGS. 7,
10a, and 10b align to create continuity with minimal gaps, in a
pattern that provides a larger surface area for improved protection
coverage while still allowing for individual replacement. Further
still, by using different designs, configurations and colors, the
collapsible modular elements 120 provide numerous possible design
configurations, patterns, logos, as well as words and pictures.
[0086] In various embodiments, the collapsible modular elements 120
may be comprised of a thin wall surface that surrounds an empty
volume 121. The collapsible modular element 120 collapses into the
empty volume 121 at a particular impact force. Alternatively, with
reference to FIG. 9, the volume 121 may be filled with one or more
energy absorption materials (first, second, etc.), optionally in
one or more layers 123a, 123b, etc. and by choosing multiple
materials to fill the volume 121 to varying levels, varying the
impact energy absorption levels may be accomplished. Whether filled
or empty, the collapsible modular elements 120 may be adhered to
the outer surface of shell 101 or a compliant layer 140 (as
discussed below), or be secured via apertures 115 or other suitable
means (as also discussed below).
[0087] The collapsible modular elements 120 may be "tuned" so as to
have different regions that collapse at different impact forces, so
as to provide more than one impact absorption capability (e.g.,
higher vs. lower impact forces). For example, the wall 122
materials and thickness may vary so that different portions of the
collapsible modular elements collapse at different impact forces.
For example, and upper portion 124 of collapsible modular element
120 may have a smaller thickness than a lower portion 125 of
collapsible modular element 120, such that the smaller thickness
collapses at a lower impact force than the larger thickness.
[0088] Similarly, by providing holes 130 of varying amounts, sizes
and shapes that pass all the way through or partially through the
wall 122, the impact force required to collapse any particular
portion of the collapsible modular element 120 can be controlled.
Additionally, whether or not the holes 130 change the impact force
required to collapse any particular portion of the collapsible
modular element 120, the holes 130 may also provide ventilation to
the helmet 100 by allowing air to flow between the user, the helmet
100 and the outside elements.
[0089] With reference to FIGS. 6a and 6b, the shell may have a
plurality of apertures 115 for receiving and releasably holding the
collapsible modular elements 120. Collapsible modular element 120
may include an attachment mechanism for securing the collapsible
modular element 120 to the helmet 100. For example, with reference
to FIGS. 8a, 8b, 8c, 9, and 10 collapsible modular element 120
contains a neck or depression 130 with a perimeter substantially
the same size as aperture 115. At the lowest edge of collapsible
modular element 120 a lip 132 is provided that is slightly bigger
than aperture 115, and as such, a collapsible modular element 120
can be inserted into aperture 115 by elastically deforming the lip
132, and when the lip 132 returns to its original shape,
collapsible modular element 120 is retained in aperture 115 in a
"snap fit" manner. As will be appreciated, any number of attachment
mechanism may be used to releasably secure collapsible modular
element 120 to the helmet 100.
[0090] In alternative embodiments, the collapsible modular elements
120 can be attached to a "soft shell" compliant layer 140 which
functions as a helmet itself (e.g., a soccer helmet) or, in some
embodiments the compliant layer 140 can be adhered to the outside
of a conventional "hard shell" 101. The compliant layer 140 is any
suitably soft, flexible material.
[0091] For example, as noted above, the collapsible modular
elements 120 can be adhered to an outer surface of the shell 101.
For example, with reference to FIG. 11a, a collapsible modular
element 120 is removably adhered to the "hard shell" 101 (or as
illustrated in FIG. 11b, a compliant "soft shell" layer 140) by any
suitable means, such as "peel and stick" adhesive, hook and loop,
suction, or the like. Inwardly or outwardly (or both) extending
flanges 117 may be provided to provide a greater surface area for
attaching the collapsible modular element 120 to the shell 101 or
the compliant layer 140.
[0092] When the compliant layer 140 is adhered to the outside of a
conventional hard shell 101, it preferably sized to a particular
helmet 100 (though other embodiments may include sizes capable of
fitting a variety of helmets 100 and sizes of the same), which is
placed over a helmet 100 and secured thereto by any suitable means
(e.g., adhesives, hook and loop, snaps, etc.).For example, with
reference to FIG. 12, the collapsible modular elements 120 are
shown adhered to a compliant layer 140 which is in turn attached to
the shell 101. As noted in connection with adherence directly to
the shell 101, the collapsible modular element 120 may be removably
adhered to the compliant layer 140 by any suitable means, such as
"peel and stick" adhesive, hook and loop, suction, or the like.
[0093] In any of the foregoing embodiments as well as those not
specifically described herein, the collapsible modular elements can
create a stand-off height 126 relative to the helmet (e.g. region
126 in FIG. 8) so that the collapsible modular elements 120 absorb
energy in a region between the shell 101 and the stand-off height
126.
[0094] The collapsible modular elements may thus provide additional
stages of impact energy absorption and may be adapted to optimize
performance for a specific sport or function by varying
characteristics such as size, location, weight, material, method of
attachment, and the like.
[0095] Still further energy absorption may be achieved by a face
mask, releasably attached to the helmet. Accordingly, improved
energy absorption may increase the helmet's ability to prevent
injury. Further, the optional ability to remove and replace the
face mask may improve cost efficiencies by decreasing the cost of
helmet refurbishment and the frequency of helmet replacement.
[0096] The face mask may be intentionally collapsible as a means of
achieving improved energy absorption. A collapsible face mask may
be designed to permanently deform upon severe impact or to
temporarily deform. Alternatively or in conjunction with
deformation, the face mask may achieve improved energy absorption
by intentionally detaching from the helmet upon impact, thereby
dissipating impact force as kinetic energy. That being said,
although an exhaustive list of means for absorbing or dissipating
energy is not included herein, one skilled in the relevant art will
appreciate that various means may be used, all of which fall within
the scope of the present disclosure.
[0097] As with other components described herein, facemask may be
made of various materials or composites, including polycarbonate
plastic, ABS plastic, carbon fiber, metals, ceramics, and the like.
The specific requirements of the facemask can determine the type of
material used, and the material used may vary in weight,
flexibility, hardness, energy-absorption ability, cost, or any
other characteristic. That being said, although an exhaustive list
of materials is not included herein, one skilled in the relevant
art will appreciate that various conventional plastics and
energy-absorbing materials may be used, all of which fall within
the scope of the present disclosure.
[0098] In the exemplary embodiment of the present disclosure, a
face mask 102 may be adapted to be releasably attached to the
helmet 100 by a helmet attachment mechanism similar to the panel
attachment mechanism described herein. The face mask 102 may be
configured as a conventional football helmet face mask and may be
releasably attached to the exterior surface of the shell 101 along
the perimeter of the shell's anterior edge. Alternatively, the face
mask 102 may be attached to the shell 101, to the layer 104, to a
panel 103, or to any other locus on the helmet 100. That being
said, the location of the face mask attachment mechanism, as well
as the configuration and orientation of the face mask, may be
adapted to meet the requirements of any sport.
[0099] Additionally, the attachment mechanism described herein may
be adapted to attach other collapsible modular helmet elements, as
required by any particular sport. Other collapsible modular helmet
elements may include a chin strap, unitary face shield, visor,
strap and ratchet apparatus, or the like.
[0100] Finally, in the foregoing specification, the disclosure has
been described with reference to specific embodiments. However, one
skilled in the art appreciates that various modifications and
changes can be made without departing from the scope of the present
disclosure as set forth in the claims below. Accordingly, the
specification is to be regarded in an illustrative rather than a
restrictive sense, and all such modifications are intended to be
included within the scope of the present disclosure.
[0101] Likewise, benefits, other advantages, and solutions to
problems have been described above with regard to specific
embodiments. However, the 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, required, or essential feature or element
of any or all of the claims. As used herein, the terms "comprises"
and "comprising," or any variations thereof, are intended to
constitute a non-exclusive inclusion, such that a process, method,
article, or apparatus that comprises a list of elements does not
include only those elements, but may include other elements not
expressly listed or inherent to such process, method, article, or
apparatus.
* * * * *