U.S. patent application number 15/855876 was filed with the patent office on 2018-12-06 for helmet with floating shell plates.
This patent application is currently assigned to Kranos IP Corporation. The applicant listed for this patent is Kranos IP Corporation. Invention is credited to Robert ERB, Vincent R. LONG, Louis Anthony VanHoutin, Cortney WARMOUTH.
Application Number | 20180343953 15/855876 |
Document ID | / |
Family ID | 64458532 |
Filed Date | 2018-12-06 |
United States Patent
Application |
20180343953 |
Kind Code |
A1 |
ERB; Robert ; et
al. |
December 6, 2018 |
HELMET WITH FLOATING SHELL PLATES
Abstract
A football helmet comprises a plastic shell having a recess
formed in the shell, a shock absorbing pad in the recess and
removably connected to the shell, and a floating shell plate
removably attached to the shock absorbing pad and further connected
to the shell by a tab-slot engagement. The helmet may further
comprise an inner liner comprising a shock absorbing element, an
inflatable liner element, and a mobility layer disposed between the
shock absorbing element and the inflatable liner element, the
mobility layer having a plurality of raised elements formed therein
to separate the shock absorbing element from the mobility layer
thereby forming a gap between the shock absorbing element and the
mobility layer, enabling relative movement of the inflatable liner
with respect to shock absorbing element.
Inventors: |
ERB; Robert; (Plandome,
NY) ; WARMOUTH; Cortney; (Edwardsville, IL) ;
LONG; Vincent R.; (St. Peters, MO) ; VanHoutin; Louis
Anthony; (Iuka, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Kranos IP Corporation |
Litchfield |
IL |
US |
|
|
Assignee: |
Kranos IP Corporation
Litchfield
IL
|
Family ID: |
64458532 |
Appl. No.: |
15/855876 |
Filed: |
December 27, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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29606636 |
Jun 6, 2017 |
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15855876 |
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29616447 |
Sep 6, 2017 |
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29606636 |
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62576467 |
Oct 24, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A42B 3/064 20130101;
A42B 3/122 20130101; A42B 3/124 20130101; A42B 3/283 20130101; A42B
3/127 20130101; A42B 3/20 20130101 |
International
Class: |
A42B 3/12 20060101
A42B003/12; A42B 3/06 20060101 A42B003/06 |
Claims
1. A football helmet comprising: a plastic shell adapted to receive
and protect the head of a wearer; the shell having a front region,
a crown region, a rear region, a left side region, a right side
region, an inner surface and an outer surface; a crown recess
formed in shell and associated with the crown region; a first slot
formed in the shell and associated with the crown recess; a crown
shock absorbing pad in the crown recess and removably connected to
the shell; a crown shell plate removably attached to the crown
shock absorbing pad and having a first tab formed therein; the
first tab engaging the first slot; and a rear recess formed in
shell and associated with the rear region; a second slot formed in
the shell and associated with the rear recess; a rear shock
absorbing pad in the rear recess and removably connected to the
shell; a rear shell plate removably attached to the rear shock
absorbing pad and having a second tab formed therein; the second
tab engaging the second slot.
2. The helmet of claim 1 wherein the crown shock absorbing pad is
composed of a single sheet of TPU having domes formed in the single
sheet to provide shock absorption.
3. The helmet of claim 1 wherein the rear shock absorbing pad is
composed of a single sheet of TPU having domes formed in the single
sheet to provide shock absorption.
4. The helmet of claim 1 wherein the crown recess has a first bank
and a second bank; the first slot is formed in the first bank and a
third slot is formed in the second bank, the crown shell plate
further comprises a third tab; and the third tab engages the third
slot.
5. The helmet of claim 4 wherein the first bank and second bank are
on opposite sides of the crown recess and are joined by a floor of
the crown recess.
6. The helmet of claim 1 wherein the rear recess has a first bank
and a second bank; the second slot is formed in the first bank and
a third slot is formed in the second bank, the rear shell plate
further comprises a third tab; and the third tab engages the third
slot.
7. The helmet of claim 6 wherein the first bank and second bank are
on opposite sides of the rear recess and are joined by a floor of
the rear recess.
8. A helmet comprising: a plastic shell adapted to receive and
protect the head of a wearer; the shell having a front region, a
crown region, a rear region, a left side region, a right side
region, an inner surface and an outer surface; a liner associated
with the inner surface, the liner comprising a shock absorbing
element, an inflatable liner element, and a mobility layer disposed
between the shock absorbing element and the inflatable liner
element, the mobility layer having a plurality of raised elements
formed therein, the plurality of raised elements separating the
shock absorbing element from the mobility layer thereby forming a
gap between the shock absorbing element and the mobility layer,
enabling relative movement of the inflatable liner with respect to
shock absorbing element.
9. The helmet of claim 8 wherein the shock absorbing element is
composed of a sheet of TPU having a plurality of hollow projections
formed therein for shock absorption.
10. The helmet of claim 8 wherein the plurality of raised elements
is a plurality of domes.
11. A football helmet comprising: a plastic shell adapted to
receive and protect the head of a wearer; the shell having a front
region, a crown region, a rear region, a left side region, a right
side region, an inner surface and an outer surface; a composite
front pad associated with the inner surface of the shell and
positioned over a front edge of the shell to at least partially
overlie the brow of a wearer; the composite front pad comprising a
shock absorbing element and a brow pad; the shock absorbing element
in the form of a sheet of plastic material having a first plurality
of hollow projections formed therein; the brow pad formed of a
resilient polymer material and having a plurality of passages
formed therein; the plurality of passages receiving the first
plurality of hollow projections.
12. The helmet of claim 11 wherein the shock absorbing element
comprises a second plurality of hollow projections formed in the
sheet of plastic material, the second plurality of hollow
projections abutting the brow pad but not received in passages.
13. The helmet of claim 11 wherein the brow pad comprises a thick
region and a thin region, the plurality of passages being formed in
the thin region, the thick region and thin region being integrally
formed thereby a recess between the thin region and the thick
region, the shock absorbing element being received in the
recess.
14. The football helmet of claim 1 further comprising: a liner
associated with the inner surface, the liner comprising a first
shock absorbing element, an inflatable liner element, and a
mobility layer disposed between the first shock absorbing element
and the inflatable liner element, the mobility layer having a
plurality of raised elements formed therein, the plurality of
raised elements separating the first shock absorbing element from
the mobility layer thereby forming a gap between the first shock
absorbing element and the mobility layer, enabling relative
movement of the inflatable liner with respect to first shock
absorbing element; and a composite front pad associated with the
inner surface of the shell and positioned over a front edge of the
shell to at least partially overlie the brow of a wearer; the
composite front pad comprising a second shock absorbing element and
a brow pad; the second shock absorbing element in the form of a
sheet of plastic material having a first plurality of hollow
projections formed therein; the brow pad formed of a resilient
polymer material and having a plurality of passages formed therein;
the plurality of passages receiving the first plurality of hollow
projections.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Application Ser. No. 62/576,467, filed Oct. 24, 2017, the
disclosure of which is incorporated herein by reference in its
entirety and for any and all purposes as if fully set forth
herein.
[0002] This application is also a continuation-in-part of U.S.
application Ser. No. 29/606,636, filed Jun. 6, 2017, the disclosure
of which is incorporated herein by reference in its entirety and
for any and all purposes as if fully set forth herein.
[0003] This application is also a continuation-in-part of U.S.
application Ser. No. 29/616,447, filed Sep. 6, 2017, the disclosure
of which is incorporated herein by reference in its entirety and
for any and all purposes as if fully set forth herein.
FIELD AND BACKGROUND OF THE INVENTION
[0004] The subject technology relates to a protective helmet for
sports play, such as a football helmet, hockey helmet, lacrosse
helmet, or the like. The subject technology is suitable for use in
full-contact sports, such as football, hockey, and lacrosse.
SUMMARY OF THE INVENTION
[0005] According to the subject technology, a helmet, such as a
football helmet comprises a durable shell formed of a suitable
material such as polycarbonate or acrylonitrile butadiene styrene
plastic, adapted to receive and protect the head of a wearer. The
helmet includes a shock-absorbing system including removable liner
components attached to the inner surface of the shell;
additionally, shock-absorbing elements are associated with the
outer surface of the shell. In an embodiment of the subject
technology, recesses are formed in the outer surface of the shell
to receive shock-absorbing elements. Floating shell plates are
provided over the shock-absorbing elements. In an embodiment of the
subject technology, a crown recess contains a shock-absorbing
cushion or sheet of thermoplastic polyurethane (TPU) material in
which shock-absorbing elements are formed by molding. A floating
shell plate is removably secured in contact with the peaks of the
shock-absorbing elements. The floating shell plate has integral
tabs formed therein which engages with niches or slots formed in
the outer shell and associated with the crown recess. The floating
shell plate is movable independently of the helmet shell in in a
direction normal to the surface of the shell, and may be movable in
a direction tangential to the helmet shell and in the normal and
tangential directions in combination. A rear recess with its
corresponding shock-absorbing TPU sheet and floating shell plate of
similar construction is also provided.
[0006] Additionally, the subject technology is directed to a helmet
liner system having relatively rigid shock absorbing elements
attached to an inner surface of the shell, inflatable liner
elements in contact with the wearer's head, and mobility layers
interposed between the shock absorbing elements and inflatable
liner elements. The mobility layers allow the inflatable liner
elements to slip relative to the shock absorbing elements and have
some degree of motion independent of the shock absorbing elements
which are connected to the shell. Thus, when the helmet is
subjected to a blow or force during sports play, acceleration of
the shell is not entirely transmitted to the wearer's head.
[0007] Additionally, the subject technology is directed to a hybrid
inner padding assembly for a helmet, including a helmet for a
full-contact sport, such as football, comprising a molded TPU shock
absorber having frustoconical projections extending from a base
sheet, mated with a pad of molded foam material, the frustoconical
projections being received snugly into openings formed in the pad
of molded foam material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The patent or application file contains at least one drawing
executed in color. Copies of this patent or patent application
publication with color drawing(s) will be provided by the Office
upon request and payment of the necessary fee.
[0009] FIG. 1 is a left, top, perspective view of a football helmet
shell according to the subject technology.
[0010] FIG. 2 is a front elevational view of a football helmet
shell according to the subject technology.
[0011] FIG. 3 is a rear elevational view of a football helmet shell
according to the subject technology.
[0012] FIG. 4 is a right side elevational view of a football helmet
shell according to the subject technology.
[0013] FIG. 5 is a left side elevational view of a football helmet
shell according to the subject technology.
[0014] FIG. 6 is a top plan view of a football helmet shell
according to the subject technology.
[0015] FIG. 7 is a bottom plan view of a football helmet shell
according to the subject technology.
[0016] FIG. 8 is a plan view of a helmet according to the subject
technology with floating shell plate removed showing shell cushions
installed to the helmet.
[0017] FIG. 9 is a plan view of a helmet according to the subject
technology.
[0018] FIG. 10 is a front view of a partially-assembled helmet
according to the subject technology.
[0019] FIG. 11 is a rear view of a helmet according to the subject
technology.
[0020] FIG. 12 is a left side view of a helmet according to the
subject technology.
[0021] FIG. 13 is a bottom view of a partially assembled helmet
according to the subject technology.
[0022] FIG. 14 is a sectional view of a partially assembled helmet
according to the subject technology.
[0023] FIG. 15 is a partially exploded view of the crown area of a
helmet according to the subject technology.
[0024] FIG. 16 is a rear perspective view of shock absorbing
elements disposed on the inner surface of a helmet according to the
subject technology.
[0025] FIG. 17 is a plan view of a floating shell plate according
to the subject technology.
[0026] FIG. 18 is a side view of a floating shell plate according
to the subject technology.
[0027] FIG. 19 is a cross-section view of a floating shell plate
according to the subject technology.
[0028] FIG. 20 is a perspective view of a floating shell plate
according to the subject technology.
[0029] FIG. 21 is a plan view of a floating shell plate according
to the subject technology.
[0030] FIG. 22 is a cross-section view of a floating shell plate
according to the subject technology.
[0031] FIG. 23 is a plan view of a shell cushion according to the
subject technology.
[0032] FIG. 24 is a cross-section view of a shell cushion according
to the subject technology.
[0033] FIG. 25 is a perspective view of a shell cushion according
to the subject technology.
[0034] FIG. 26 is a perspective view of a shell cushion according
to the subject technology.
[0035] FIG. 27 is a plan view of a shell cushion according to the
subject technology.
[0036] FIG. 28 is a detail view of ridges of the shell cushion of
FIG. 27 according to the subject technology.
[0037] FIG. 29 is a perspective view of a front area shock
absorbing element according to the subject technology.
[0038] FIG. 30 is a bottom view of a front area shock absorbing
element according to the subject technology.
[0039] FIG. 31 is a cross-sectional view of a front area shock
absorbing element according to the subject technology.
[0040] FIG. 32 is a top view of a front area shock absorbing
element according to the subject technology.
[0041] FIG. 33 is a rear view of a front pad according to the
subject technology.
[0042] FIG. 34 is a cross-sectional view of a front pad according
to the subject technology.
[0043] FIG. 35 is a perspective view of a front pad according to
the subject technology.
[0044] FIG. 36 is a rear view of a front pad assembly according to
the subject technology.
[0045] FIG. 37 is a front view of a front pad assembly according to
the subject technology.
[0046] FIG. 38 is a front view of a front pad assembly according to
the subject technology, inside the comfort layer fabric.
[0047] FIG. 39 is a rear view of a front pad assembly according to
the subject technology, inside the comfort layer fabric.
[0048] FIG. 40 is a rear view of a lateral assembly of shock
absorbing elements according to the subject technology.
[0049] FIG. 41 is a rear view of a central element of a lateral
assembly of shock absorbing elements according to the subject
technology.
[0050] FIG. 42 is a cross-sectional view of a central element of a
lateral assembly of shock absorbing elements according to the
subject technology.
[0051] FIG. 43 is a right side view of a central element of a
lateral assembly of shock absorbing elements according to the
subject technology.
[0052] FIG. 44 is a rear view of a top element of a lateral
assembly of shock absorbing elements according to the subject
technology.
[0053] FIG. 45 is a cross-sectional view of a top element of a
lateral assembly of shock absorbing elements according to the
subject technology.
[0054] FIG. 46 is a left side view of a left wing of a lateral
assembly of shock absorbing elements according to the subject
technology.
[0055] FIG. 47 is a rear view of a left wing of a lateral assembly
of shock absorbing elements according to the subject
technology.
[0056] FIG. 48 is a cross-sectional view of a left wing of a
lateral assembly of shock absorbing elements according to the
subject technology.
[0057] FIG. 49 is a rear view of a right wing of a lateral assembly
of shock absorbing elements according to the subject
technology.
[0058] FIG. 50 is a cross-sectional view of a right wing of a
lateral assembly of shock absorbing elements according to the
subject technology.
[0059] FIG. 51 is a right side view of a right wing of a lateral
assembly of shock absorbing elements according to the subject
technology.
[0060] FIG. 52 is a rear view of a lateral mobility layer according
to the subject technology.
[0061] FIG. 53 is a side view of a lateral mobility layer according
to the subject technology.
[0062] FIG. 54 is a front view of a lateral mobility layer
according to the subject technology.
[0063] FIG. 55 is a perspective view of an inflatable lateral liner
according to the subject technology.
[0064] FIG. 56 is a front view of an inflatable lateral liner
according to the subject technology.
[0065] FIG. 57 is a rear view of an inflatable lateral liner
according to the subject technology.
[0066] FIG. 58 is a side view of an inflatable lateral liner
according to the subject technology.
[0067] FIG. 59 is a detail view of an inflatable cell of an
inflatable lateral liner according to the subject technology.
[0068] FIG. 60 is a cross sectional view of an inflatable lateral
liner according to the subject technology.
[0069] FIG. 61 is a front view of the assembly of a lateral
mobility layer to an inflatable lateral liner according to the
subject technology.
[0070] FIG. 62 is a side view of the assembly of a lateral mobility
layer to an inflatable lateral liner according to the subject
technology.
[0071] FIG. 63 is a plan view of the assembly of the lateral TPU
assembly, lateral mobility layer, and inflatable lateral liner of
the subject technology.
[0072] FIG. 64 is a plan view of the assembly of the lateral TPU
assembly, lateral mobility layer, and inflatable lateral liner of
the subject technology.
[0073] FIG. 65 is a detail view of the assembly of the lateral TPU
assembly, lateral mobility layer, and inflatable lateral liner of
the subject technology.
[0074] FIG. 66 is a detail view of the assembly of the lateral TPU
assembly, lateral mobility layer, and inflatable lateral liner of
the subject technology, showing how the valve assembly of the
inflatable lateral liner is assembled through the keyway in the
lateral TPU assembly.
[0075] FIG. 67 is a perspective view of a crown shock absorbing
element according to the subject technology.
[0076] FIG. 68 is a bottom view of a crown shock absorbing element
according to the subject technology.
[0077] FIG. 69 is a cross-sectional view of a crown shock absorbing
element according to the subject technology.
[0078] FIG. 70 is a top view of a crown shock absorbing element
according to the subject technology.
[0079] FIG. 71 is a front view of a crown mobility layer according
to the subject technology.
[0080] FIG. 72 is a rear view of a crown mobility layer according
to the subject technology.
[0081] FIG. 73 is a side view of a crown mobility layer according
to the subject technology.
[0082] FIG. 74 is a front view of a crown lateral liner according
to the subject technology.
[0083] FIG. 75 is a cross-sectional view of a crown lateral liner
according to the subject technology.
[0084] FIG. 76 is a perspective view of the assembly of a crown
inflatable element, crown mobility layer, and crown shock absorbing
element according to the subject technology.
[0085] FIG. 77 is a perspective view of the assembly of a crown
inflatable element, crown mobility layer, and crown shock absorbing
element according to the subject technology.
[0086] FIG. 78 is a top view of a face guard twist-release mount
according to the subject technology.
[0087] FIG. 79 is a cross-sectional view of a face guard
twist-release mount according to the subject technology.
[0088] FIG. 80 is a front view of a face guard twist-release mount
according to the subject technology.
[0089] FIG. 81 is a cross-sectional view of a face guard
twist-release mount according to the subject technology.
[0090] FIG. 82 is a rear view of a face guard twist-release mount
according to the subject technology.
[0091] FIG. 83 is a right side view of a right outer brace for a
cheek support according to the subject technology.
[0092] FIG. 84 is a left side view of a right outer brace for a
cheek support according to the subject technology.
[0093] FIG. 85 is a front view of a right outer brace for a cheek
support according to the subject technology.
[0094] FIG. 86 is a cross-sectional view of a right outer brace for
a cheek support according to the subject technology.
[0095] FIG. 87 is a right side view of a left outer brace for a
cheek support according to the subject technology.
[0096] FIG. 88 is a left side view of a left outer brace for a
cheek support according to the subject technology.
[0097] FIG. 89 is a front view of a left outer brace for a cheek
support according to the subject technology.
[0098] FIG. 90 is a cross-sectional view of a left outer brace for
a cheek support according to the subject technology.
[0099] FIG. 91 is a view of the outer face of an inner plate for a
right cheek support
[0100] FIG. 92 is a view of the inner face of an inner plate for a
right cheek support
[0101] FIG. 93 is a view of the outer face of an inner plate for a
left cheek support
[0102] FIG. 94 is a view of the inner face of an inner plate for a
left cheek support
[0103] FIG. 95 is a plan view of a left side cheek pad for a cheek
support according to the subject technology.
[0104] FIG. 96 is a bottom view of a left side cheek pad for a
cheek support according to the subject technology.
[0105] FIG. 97 is a plan view of a right side cheek pad for a cheek
support according to the subject technology.
[0106] FIG. 98 is a bottom view of a right side cheek pad for a
cheek support according to the subject technology.
[0107] FIG. 99 is a plan view of a pad of resilient polymer foam
material which may be disposed in the inflatable cells of the
inflatable liners according to the subject technology.
[0108] FIG. 100 is a plan view of a pad of resilient polymer foam
material which may be disposed in the inflatable cells of the
inflatable liners according to the subject technology.
[0109] FIG. 101 is a plan view of a pad of resilient polymer foam
material which may be disposed in the inflatable cells of the
inflatable liners according to the subject technology.
[0110] FIG. 102 is a top view of a shock absorbing element having a
dense distribution of cones according to the subject
technology.
[0111] FIG. 103 is a side view of a shock absorbing element having
a dense distribution of cones according to the subject
technology.
[0112] FIG. 104 is a cross-sectional view of a shock absorbing
element having a dense distribution of cones according to the
subject technology.
[0113] FIG. 105 is a front view of a face guard for attachment to a
helmet according to the subject technology.
[0114] FIG. 106 is a left side view of a face guard for attachment
to a helmet according to the subject technology.
[0115] FIG. 107 is a front view of a face guard for attachment to a
helmet according to the subject technology.
[0116] FIG. 108 is a left side view of a face guard for attachment
to a helmet according to the subject technology.
[0117] FIG. 109 is a front view of a face guard for attachment to a
helmet according to the subject technology.
[0118] FIG. 110 is a left side view of a face guard for attachment
to a helmet according to the subject technology.
[0119] FIG. 111 is a front view of a face guard for attachment to a
helmet according to the subject technology.
[0120] FIG. 112 is a left side view of a face guard for attachment
to a helmet according to the subject technology.
[0121] FIG. 113 is a front view of a face guard for attachment to a
helmet according to the subject technology.
[0122] FIG. 114 is a left side view of a face guard for attachment
to a helmet according to the subject technology.
[0123] FIG. 115 is a front view of a face guard for attachment to a
helmet according to the subject technology.
[0124] FIG. 116 is a left side view of a face guard for attachment
to a helmet according to the subject technology.
[0125] FIG. 117 is a front view of a face guard for attachment to a
helmet according to the subject technology.
[0126] FIG. 118 is a left side view of a face guard for attachment
to a helmet according to the subject technology.
[0127] FIG. 119 is a front view of a face guard for attachment to a
helmet according to the subject technology.
[0128] FIG. 120 is a left side view of a face guard for attachment
to a helmet according to the subject technology.
[0129] FIG. 121 is a front view of a face guard for attachment to a
helmet according to the subject technology.
[0130] FIG. 122 is a left side view of a face guard for attachment
to a helmet according to the subject technology.
[0131] FIG. 123 is a front view of a face guard for attachment to a
helmet according to the subject technology.
[0132] FIG. 124 is a left side view of a face guard for attachment
to a helmet according to the subject technology.
[0133] FIG. 125 is a front view of a face guard for attachment to a
helmet according to the subject technology.
[0134] FIG. 126 is a left side view of a face guard for attachment
to a helmet according to the subject technology.
[0135] FIG. 127 is a front view of a face guard for attachment to a
helmet according to the subject technology.
[0136] FIG. 128 is a left side view of a face guard for attachment
to a helmet according to the subject technology.
DETAILED DESCRIPTION OF THE DRAWINGS
[0137] As shown for example in FIGS. 1-6, helmet 1 shell according
to the subject technology comprises a shell 10 composed of a
suitable material such as polycarbonate, reinforced fiberglass,
carbon fiber composite, or acrylonitrile butadiene styrene (ABS)
plastic. Preferably the material of shell 10 is strong enough to
resist impacts but retaining some flexibility. Shell 10 may be
manufactured by means known to those of skill in the art including
thermoplastic injection molding and thermoforming. Shell 10 has
bilateral symmetry about a plane of symmetry P bisecting shell 10.
Shell 10 has a front area, left area, right area, and rear area.
Shell 10 has a front edge 29, left edge 30, right edge 31, and
bottom edge 32. Edges 29-31 define a face opening of shell 10. Left
and right edges 30 and 31 meet bottom edge 32 at curved transitions
to define a left earflap 33 and right earflap 34 of a conventional
type, size and extent known to the art, in the left area and right
area respectively. Shell 10 may be formed as two molded
hemispheres, particularly a left hemisphere and a right hemisphere
which are joined together along the plane of symmetry P.
[0138] Notable features of shell 10 according to the subject
technology are recesses formed in the shell, which according to an
embodiment are lying in and bisected by plane of symmetry P, which
are adapted to contain shock absorbing elements covered by floating
shell plates, as hereinafter described.
[0139] Crown recess 12 is formed in shell 10 for receiving crown
shock absorbing pad or cushion 70 and crown floating shell plate 60
as hereinafter described. Crown recess 12 has floor 14 defined by
front bank 15, rear bank 16, left bank 17, right bank 18. Banks
15-18 are preferably formed to slope at an obtuse angle from the
outer surface of the surrounding shell 10 to floor 14.
Alternatively, banks 15-18 are formed to slope at a right angle, or
approximately a right angle. Each of banks 15-18 may have formed
therein one more niches or through-going slots. In the embodiment
of FIGS. 1-6, front bank 15 has two through-going slots 19 and rear
bank 16 has two through-going slots 20. Preferably, crown recess 12
is bisected by plane P and has bilateral symmetry about plane
P.
[0140] Rear recess 21 is formed in shell 10 for receiving rear
shock absorbing pad 70 and crown floating shell plate 80 as
hereinafter described. Rear recess 21 has floor 22 defined by front
bank 23, rear bank 24, left bank 25, right bank 26. Banks 23-26 are
preferably formed to slope at an obtuse angle from the outer
surface of the surrounding shell 10 to floor 22. Alternatively,
banks 23-26 are formed to slope at a right angle, or approximately
a right angle. Each of banks 23-26 may have formed therein one more
niches or through-going slots. In the embodiment of FIGS. 1-6,
front bank 23 has two through-going slots 27 and rear bank 24 has
two through-going slots 28. Preferably, rear recess 12 is bisected
by plane P and has bilateral symmetry about plane P.
[0141] In the embodiments of FIGS. 1-6, crown recess 12 is longer
than rear recess 21 and has the same width as rear recess 21.
Alternatively, crown recess 12 is wider than rear recess 21.
Alternatively, crown recess 12 is narrower than rear recess 21.
Alternatively, crown recess 12 has the same length as rear recess
21. Alternatively, rear recess 21 is longer than crown recess
12.
[0142] Outside of recesses 12 and 21, shell 10 is divided into
zones of unequal elevation delimited from and connected to
neighboring zones by sloped banks.
[0143] A first zone 100 of highest elevation includes a forehead
region 35 which is rectangular, roughly rectangular, or
trapezoidal, and sweeping region 39.
[0144] In the embodiment of FIGS. 1-6, forehead region 35 extends
from front edge 29 toward crown recess 12 and is partially defined
by banks 36, 37, 38. Bank 38 slopes toward and abuts front bank 15
of crown recess 12. The top edge of forehead region 35 may be the
same width as floor 14. Forehead region 35 may broaden from bank 38
in the direction of front edge 29.
[0145] First zone 100 extends from forehead region 35 along front
edge 29 and forms sweeping region 39 which sweeps across the shell
from left edge 30 to right edge 31. Rear recess 21 is located in
sweeping region 39 of first zone 100. Sweeping region 39 can be
viewed as consisting of a right temporal wing 101 and a left
temporal wing 102, with rear recess 21 located in the rear of the
helmet where right temporal wing 101 and left temporal wing 102
meet. Right temporal wing 101 begins at the right edge 31 of shell
10 and sweeps across the right side of shell 10 above earholes 48,
49 associated with the right earflap 34 toward rear recess 21. Left
temporal wing 102 begins at the left edge 30 of shell 10 and sweeps
across the left side of shell 10 above earholes 48, 49 associated
with the left earflap 33 toward rear recess 21. First zone 100,
forehead region 35, sweeping region 39, right temporal wing 101 and
left temporal wing 102 strengthen shell 10 by imparting additional
resistance to flexing, and thereby improve the strength and
durability of the helmet.
[0146] First zone 100 may include provisions for attaching
loopstraps to shell 10. The provisions may include recesses 103
formed in first zone 100 in which holes may be formed for mounting
loopstraps to shell 10 by means of screws and T-nuts.
[0147] A second zone 110 of lower elevation than first zone 100 is
partially surrounded by first zone 100. Crown recess 12 is located
in second zone 110. Crown recess 12 may be oriented lengthwise
along the plane P and extend from the edge of first zone 100 and/or
forehead region 35 to the edge of first zone 100, or the edge of
second zone 10, or more particularly the border between first zone
100 and second zone 100. Second zone 110 rises to meet first zone
100 at points adjacent to rear bank 16 of crown recess 12. Second
zone 110 may have through-going holes or slots for ventilation. In
the embodiment shown in FIGS. 1-6, second zone 110 has elongated
ventilation slots 44, 45 alongside banks 40, 41, respectively, in
the right area of the helmet, and elongated ventilation slots 46,
47 alongside banks 42, 43, respectively, in the left area of the
helmet. Ventilation slots 44, 45 are not co-linear, and define
between them an angle greater than 90 degrees. Similarly,
ventilation slots 46, 47 are not co-linear, and define between them
an angle greater than 90 degrees.
[0148] A third zone 120 of lower elevation than first zone 100 is
adjacent to sweeping region 39 of first zone 100. Third zone 120 is
joined to sweeping region 39 by bank 11, and is joined to fourth
zone 130 by bank 13. Third zone 120 sweeps across the shell from
left earflap 33 to right earflap 34. Third zone 120 may have one or
more through-going ear holes associated with the left earflap 33
and right earflap 34. In the embodiment of FIGS. 1-6, each earflap
is associated with two earholes, specifically, a convex earhole 48
and a concave earhole 49. Raised rear area, or back shelf, 50 in
third zone 120 is bounded on the left edge and right edge by banks
sloping down to third zone 120; bounded on the top by the bank 11
sloping down from sweeping region 39 of first zone 100 to third
zone 120; and bounded on the bottom by the bank 13 sloping down
from third zone 120 to fourth zone 130. Raised rear area, or back
shelf, 50 imparts greater flexural resistance to shell 10.
Through-going elongated ventilation slots 58 may be formed in
raised rear area 50. Through-going elongated ventilation slots 59
may be formed in third zone 120.
[0149] A fourth zone 130 of lowest elevation than third zone 120 is
adjacent to third zone 120. Fourth zone 130 is bounded by bottom
edge 32 and sweeps across shell 10 from left earflap 33 to right
earflap 34.
[0150] Turning now to the shock absorbers and floating shell plates
disposed in shell recesses, as shown for example in FIGS. 17-19, a
floating shell plate 50 for crown recess 12 according to an
embodiment of the subject technology is composed of a single sheet
of material suitable for use in a helmet shell, for example, ABS,
polycarbonate, reinforced fiberglass, or carbon fiber composite.
Floating shell plate 50 may be manufactured by injection molding or
thermoforming. Floating shell plate 50 is sized and shaped to serve
as a lid or cover over crown recess 12. Floating shell plate 50 has
a body 51 and tabs extending from body 51 at the periphery of body
51. In an embodiment of the present technology, floating shell
plate has two tabs 52 positioned at a top edge of body 51 and two
tabs 53 positioned on the opposite (bottom) edge of the body 51.
Body 51 is curved to conform to the outer curvature of the profile
of second zone 100 shell 10. Tabs 52, 53 are sized and adapted to
engage with niches or slots 19, 20 in the walls of crown recess 12.
Accordingly, tabs 52, 53 extend downwardly at an angle from the
periphery of body and each tab may terminate in a bent end which is
adapted to be inserted into slots 19, 20 in the walls of crown
recess 12, thereby removably retaining the floating shell plate
over crown recess 12. Alternatively, each tab 52, 53 may terminate
in a straight end. Left and right edges of body 51 may be formed
with a plurality of segments 54 connected by angled transition
portions 55 to form crenulations or crenulated edges along the left
and right of body 51. To further secure the connection of floating
shell plate 50 to shell 10, the body 51 may be provided with
through-going holes 56 for receiving a screw or bolt connecting
plate 50 to cushion 70, or to shell 10, or to both. Floating shell
plate 50 may have a thickness of 0.090 inches or approximately
0.090 inches. Floating shell plate 50 may have one or more holes 56
or elongated slots 57 formed therein.
[0151] As shown for example in FIGS. 27-28, a shock absorbing
cushion 70 for crown recess 12 according to an embodiment of the
subject technology is composed of a single flexible sheet of TPU
material by molding or thermoforming. According to an embodiment of
the subject technology, cushion 70 is sized and adapted to nest and
fit closely within crown recess 12 of the shell.
[0152] Domes are formed in a base sheet 73 of TPU material and are
distributed over a coverage area to provide shock absorption
between floor 14 and floating shell plate 50. Base sheet 73 is
formed in a curved shape to match the curvature of floor 14. Domes
may be oriented outwardly (i.e. in the direction away from floor
14), or inwardly (toward floor 14, thereby forming cups). In an
embodiment of the subject technology, rows 74 of aligned,
alternating domes 71 and cups 72 are formed in base sheet 73 (only
one such row is numbered in the figures). Preferably, the sequence
of domes and cups in a row is the inverse of the sequence in the
neighboring row. Other arrangements of domes and/or cups in base
sheet 73 is within the scope of the subject technology, for
example, all domes, all cups, rows of cups alternating with
adjacent rows of domes. Holes 75 may be formed in the base sheet 73
for attachment of cushion 70 to shell 10. The holes 75 may be
defined and surrounded by a thickened area 76 to strengthen the
part. Holes 76 may be formed in the base sheet 73 for attachment of
plate 50 to cushion 70, or to shell 10, or both. Holes 75, 76 may
be defined and surrounded by a thickened area to strengthen the
part. The edges of the cushion 70 may be formed as thickened ridges
80, 81 interrupted by cutouts. In an embodiment of the subject
technology, four cutouts 78, 79 are formed in the ridges, two
cutouts 78 on a top edge of the pad and two cutouts 79 on the
opposite, bottom edge. Cutouts 78, 79 coincide with tabs 52, 53 to
permit tabs 52, 53 to engage with niches or slots 19, 20,
respectively. In an embodiment of the subject technology, four
ridges 80, 81 are formed at the edges of base sheet 73. Preferably,
ridges 80, 81 are sized so as not to protrude above the surface
defined by plate 50. Ridges 80 at the top edge and bottom edge of
base sheet 73 may be formed with a triangular cross-section, the
peak 82 of the triangle at the point of contact between ridges 80
and base sheet 73, the base 83 of the triangle oriented away from
base sheet 73 and floor 14. In that embodiment, one side 84 of the
triangle is formed to conform with the slope of the adjacent bank
15 or 16 so that when cushion 70 assembled to crown recess 12, side
84 closely contacts bank 15 or 16. Additionally, base 83 may be
formed to conform with the curvature of floating shell plate 50 so
that the curvature is smoothly continued from plate 50 over base
83. Preferably, the length of ridges 80 is less than the distance
between tabs 52, 53, to define a gap between the left and right
ends of ridges 80 and the inner edges of tabs 52, 53, so that
floating shell plate 50 is permitted to move in a direction
tangential to the surface of shell 10.
[0153] As best seen in FIG. 8, cushion 70 is assembled to crown
recess 12 so that the peaks of any cups 72 are contacting floor 14
and base sheet 73 is mostly suspended above floor 14, although base
sheet 73 may contact floor 14 at points where it is not supported
by adjacent cups 72. In an embodiment in which cushion 70 has no
cups and only domes, base sheet 73 is contacting floor 14. Cushion
70 may be removably secured to shell 10 by screws and T-nuts
passing through holes 75 and corresponding holes in floor 14.
Cutouts 78, 79 align with niches or slots 19, 20 so that cushion 70
and base sheet 73 are not obstructing niches or slots 19, 20. As
best seen in FIG. 9, crown floating shell plate 50 is assembled
over cushion 70. Tabs 52, 53 are inserted into niches or slots 19,
20 via cutouts 78, 79 in cushion 70. The crenulations, holes 56
and/or elongated slots 57 may expose portions of cushion 70.
Floating shell plate 50 is removably attached by a screw or bolt
passing through holes 56 connecting plate 50 to cushion 70, or to
shell 10, or to both. In an embodiment in which floating shell
plate 50 is removably attached to cushion 70 but not to shell 10,
advantageously, a relatively large hole may be formed in floor 14
below the hardware (screw or bolt) connecting plate 50 to cushion
70, so that the hardware is not normally contacting floor 14.
[0154] Rear recess 21 receives shock absorbing cushion 90 and
floating shell plate 60, which are similar in form and function to
shock absorbing cushion 70 and floating shell plate 50,
respectively. As shown for example in FIGS. 20-22, a floating shell
plate 60 for rear recess 21 according to an embodiment of the
subject technology is composed of a single sheet of polymer
material suitable for use in a helmet shell, for example, ABS,
polycarbonate, reinforced fiberglass, or carbon fiber composite.
The floating shell plate 60 may be formed by injection molding or
thermoforming. Floating shell plate 60 has a body 61 and tabs 62,
63 extending from the body 61 at the periphery of the body.
Floating shell plate 60 is sized and shaped to serve as a lid or
cover over rear recess 21. In an embodiment of the present
technology, floating shell plate has two tabs 62 positioned at a
top edge of the body and two tabs 63 positioned on the opposite,
bottom, edge of the body. Body 61 is curved to conform to, and
continue, the outer curvature of the shell profile of sweeping
region 39 of first zone 100. Tabs 63, 63 are sized and adapted to
engage with the niches or slots 27, 28 in the walls of the rear
recess 21. Accordingly, tabs 61, 62 extend downwardly at an angle
from the periphery of body and each tab may terminate in a bent end
which is adapted to be inserted into the slots 27, 28 in the banks
of the rear recess 21, thereby removably retaining floating shell
plate 60 in rear recess 21. Alternatively, each tab 62, 63 may
terminate in a straight end. Left and right edges of body 61 may be
formed with segments 64 connected by angled transition portion 65.
To further secure the connection of floating shell plate 60 to
shell 10, the body 61 may be provided with through-going hole 66
for receiving a screw or bolt connecting plate 60 to cushion 90, or
to shell 10, or to both. One or more slots 67 may be formed in body
61. Floating shell plate 60 may have a thickness of 0.090 inches or
approximately 0.090 inches. Floating shell plate 60 may have one or
more hole(s) 66 or elongated slots 67 formed therein.
[0155] As shown for example in FIGS. 23-26, a shock absorbing
cushion 90 for rear recess 21 according to an embodiment of the
subject technology is composed of a single flexible sheet of TPU
material by molding or thermoforming. According to an embodiment of
the subject technology, cushion 90 is sized and adapted to nest and
fit closely within rear recess 21 of the shell. Domes are formed in
a base sheet 93 of TPU material and are distributed over a coverage
area to provide shock absorption between floor 22 and floating
shell plate 60. Base sheet 93 is formed in a curved shape to match
the curvature of floor 22. Domes may be oriented outwardly (i.e. in
the direction away from floor 22), or inwardly (toward floor 22,
thereby forming cups). In an embodiment of the subject technology,
a row 94 of aligned, alternating domes 91 and cups 92 is formed in
the forward edge of base sheet 93. A second row 86 of domes is
formed amid base sheet 93. A third row 87 of cups is formed in a
rear edge of base sheet 93. Other arrangements of domes and/or cups
in base sheet 93 is within the scope of the subject technology, for
example, all domes, all cups, rows of cups alternating with
adjacent rows of domes. Holes 95 may be formed in the base sheet 93
for attachment of cushion 90 to shell 10. The holes 95 may be
defined and surrounded by a thickened area 76 to strengthen the
part. Holes 89 may be formed in the base sheet 93 for attachment of
plate 90 to cushion 90, or to shell 10, or both (more than one hole
could be formed and used for this purpose). Holes 89, 95 may be
defined and surrounded by a thickened area to strengthen the part.
The edges of the cushion 90 may be formed as thickened ridges 96,
97 interrupted by cutouts. In an embodiment of the subject
technology, four cutouts 98, 99 are formed in the ridges, two
cutouts 98 on a top edge of the pad and two cutouts 99 on the
opposite, bottom edge. Cutouts 98, 99 coincide with tabs 62, 63 to
permit tabs 62, 63 to engage with niches or slots 27, 28,
respectively. In an embodiment of the subject technology, four
ridges 80, 81 are formed at the edges of base sheet 93. Preferably,
ridges 96, 97 are sized so as not to protrude above the surface
defined by plate 60. Ridges 96 at the top edge and bottom edge of
base sheet 93 may be formed with a triangular cross-section, the
peak 103 of the triangle at the point of contact between ridges 96
and base sheet 93, the base 104 of the triangle oriented away from
base sheet 93 and floor 22. In that embodiment, one side 105 of the
triangle is formed to conform with the slope of the adjacent bank
23 or 24 so that when cushion 90 assembled to rear recess 21, side
105 closely contacts bank 23 or 24. Additionally, base 104 may be
formed to conform and continue with the curvature of floating shell
plate 60 so that the curvature is smoothly continued from plate 60
over base 104. Preferably, the length of ridges 96 is less than the
distance between tabs 61, 62, to define a gap between the left and
right ends of ridges 80 and the inner edges of tabs 61, 62, so that
floating shell plate 50 is permitted to move in a direction
tangential to the surface of shell 10. The ridges 97 on the left
and right edges of cushion 90 may be formed with a relatively thick
lower segment 106 connected to a relatively thin upper segment 107
by an angled transition portion, forming a shelf.
[0156] FIG. 8 in particular shows a helmet 1 according to the
subject technology with the floating shell plates removed, to show
the assembly of cushions 70, 90 to shell 10 in recesses 12, 21.
[0157] FIG. 14 shows a sectional rendering of shell 10, floating
shell plates 50, 60, cushions 70, 90, with an inner plate for a
cheek support attached to the right earflap.
[0158] FIG. 15 shows a partially exploded view of floating shell
plates 50, 60 with respect to shell 10. Cushion 70 is shown as
installed in crown recess 12.
[0159] In use in sports play, when helmet 1 is subjected to forces
and blows on and around plate 50, a component of force normal (i.e.
perpendicular) to the surface of plate 50 compresses one or more of
domes 71 and/or cups 72, between plate 50 and floor 14, which
compression is resiliently resisted by the TPU material of cushion
70, domes 71 and/or cups 72. And while the material of plate 50 is
somewhat flexible, the curvature of body 51 of plate 50 gives it
sufficient rigidity that the compressive normal force is
distributed over a number of domes 71 and/or cups 72. A component
of force tangential to the surface of plate 50 urges plate 50 to
move in the direction of the force. In response to the tangential
component of force (i.e., the component parallel to the surface of
plate 50), plate 50 may move or slide, with consequent resilient
deformation of cushion 70 and its base sheet 73 by the action of
plate 50 and its connection to cushion 70.
[0160] After the force is removed, cushion 70 and its base sheet
73, domes 71 and/or cups 72 resiliently rebound and return to their
original shape, and plate 50 is restored to its original position.
In this way, plate 50 is resiliently movable independently of shell
10 when subjected to forceful blows, reacting in multiple
directions to help better distribute the energy of an impact. In
embodiments in which the length of ridges 80 is less than the
distance between tabs 52, 53, to define a gap between the left and
right ends of ridges 80 and the inner edges of tabs 52, 53,
floating shell plate 50 has more freedom of movement in the lateral
or tangential direction, which is advantageous for this mode of
operation.
[0161] Similarly, when helmet 1 is subjected to forces and blows on
and around plate 60, a component of force normal (i.e.
perpendicular) to the surface of plate 60 compresses one or more of
domes 91 and/or cups 92, between plate 60 and floor 22, which
compression is resiliently resisted by the TPU material of cushion
90, domes 91 and/or cups 92. And while the material of plate 60 is
somewhat flexible, the curvature of body 61 of plate 60 gives it
sufficient rigidity that the compressive normal force is
distributed over a number of domes 91 and/or cups 92. A component
of force tangential to the surface of plate 60 urges plate 60 to
move in the direction of the force. In response to the tangential
component of force (i.e., the component parallel to the surface of
plate 60), plate 60 may move or slide, with consequent resilient
deformation of cushion 90 and its base sheet 93 by the action of
plate 60 and its connection to cushion 90.
[0162] After the force is removed, cushion 90 and its base sheet
93, domes 91 and/or cups 92 resiliently rebound and return to their
original shape, and plate 60 is restored to its original position.
In this way, plate 60 is resiliently movable independently of shell
10 when subjected to forceful blows, reacting in multiple
directions to help better distribute the energy of an impact. In
embodiments in which the length of ridges 96 is less than the
distance between tabs 62, 63, to define a gap between the left and
right ends of ridges 96 and the inner edges of tabs 62, 63,
floating shell plate 60 has more freedom of movement in the lateral
or tangential direction, which is advantageous for this mode of
operation.
[0163] Helmet 1 may have attached to shell 10 cheek supports, such
as those disclosed in U.S. patent application Ser. No. 15/456,279,
published as U.S. Patent Published Patent Application 2017/0291095,
for "Football Helmet with Cheek Supports," the entire disclosure of
which is hereby incorporated by reference, which is assigned to the
assignee of the present application. The disclosed cheek supports,
which may also be used in the present technology of helmet 1,
consist of an outer brace, an inner plate, and cheek pads
associated with the inner plate, all of which are more particularly
described in the incorporated pending patent application. FIGS.
83-90 show views of outer braces which may be used in helmet 1, as
alternatives to the outer braces described in the incorporated
pending patent application. FIGS. 91-94 show views of inner plates
which may be used in helmet 1, as alternatives to the outer braces
described in the incorporated pending patent application. FIGS.
95-98 show views of cheek pads which may be used in helmet 1, as
alternatives to the outer braces described in the incorporated
pending patent application. The function, materials, dimensions and
structure of the outer brace, inner plate, cheek pads which may be
used in helmet 1 are as described in the incorporated pending
patent application. When helmet 1 is worn by a football player, as
more particularly described in the incorporated pending patent
application, the cheek pads are held firmly against the wearer's
cheek to at least partially overlay the area of the zygomatic bone.
The cheek pads exert forces bearing against the wearer's cheek area
to help retain the helmet 1 on the head during sports play. The
padding provided by the cheek pad also provides protection to that
area against collisions.
[0164] Helmet 1 has inner padding elements removably attached to
the inner surface of shell 10 to provide further shock absorption,
to help better size the helmet to the wearer, and for the comfort
of the wearer. Inner padding elements in helmet 1 include shock
absorbing elements made of TPU consisting of a base sheet of TPU
with projecting hollow cones, such as those described in U.S. Pat.
No. 9,622,533 for "Single-layer padding system," the entire
disclosure of which is hereby incorporated by reference, which is
assigned to the assignee of the present application. The TPU
elements are installed in contact with the inner surface of shell
10.
[0165] FIGS. 67-70 show views of a TPU crown shock absorbing
element that may be installed in the helmet 1 of the subject
technology, in the crown area of helmet 1. According to the
embodiment shown in FIGS. 67-70, crown TPU element 160 comprises a
base sheet 161 having hollow frusto-conical projections 162 (only
one is numbered) extending therefrom and distributed over the
coverage area to provide shock absorption. Squared hollow cones 163
also provide shock absorption, and have T-nuts at their distal ends
for attaching the assembly to the inner surface of shell 10.
Projections 162 may have closed distal ends (i.e., the projections
terminate in a surface which closes the upper end of the
projections), alternatively, some or all of projections 162 may
have open distal ends. In either case, the distal ends of
projections 162 and 163 are slanted such that when installed, the
distal ends overall conform to and closely contact the inner
surface of shell 10. Crown TPU element 160 is curved overall to
closely contact the inner surface of shell 10. Projections 162 and
163 may be each be connected to one or more of its neighbors by
connecting ribs 164 (only one is numbered). Connecting ribs 164
stabilize element 160 by tending to support projections 162 and 163
and tending to prevent projections 162 and 163 from tipping or
leaning when subjected to a shock or blow during sports play.
Supported by ribs 164, projections 162 and 163 preferentially
collapse in a resilient manner when subjected to shocks. Keyway 165
may be formed in base sheet 161 for passage of a tube for inflation
of an inflatable liner component. Keyway 165 may be formed with
retaining projections 166 to retain the inflation tube in keyway
165 during assembly, as hereinafter described in connection with
the description of the crown inflatable liner.
[0166] FIGS. 29-32 show views of a TPU shock absorbing element,
particularly a front pad insert, that may be installed in the
helmet 1 of the subject technology, as hereinafter described.
[0167] FIGS. 29-32 show views of a TPU shock absorbing element
which may be used in a front area of helmet 1, above the front edge
29 of the shell. This element may be used in conjunction with a
front pad. FIGS. 34-35 show views of a front pad, which is made of
a resilient polymer material such as EVA or slow-recovery EVA. The
front pad includes recesses or through-going holes for receiving
TPU cones of the front area TPU shock absorbing element, so that
the element and pad may be assembled together to form a composite
TPU/EVA front shock absorbing element. FIGS. 36-37 show views of
the assembly of the element and pad. FIGS. 38-39 show views of the
composite front pad, complete with its soft padded comfort
layer.
[0168] As shown in FIGS. 29-32, TPU element 140 comprises a base
sheet 141 having hollow frusto-conical projections extending
therefrom to provide shock absorption. In the embodiment of this
element as shown, element 140 comprises seven long cones 142 (only
one is numbered), two short cones 143, and two squared cones 144.
Squared cones 144 have T-nuts at their distal ends for attaching
the assembly to the inner surface of shell 10.
[0169] Turning specifically to the EVA pad, as shown in FIGS.
33-35, pad 145 has a thick region 149 integrally formed with a thin
region 150, thereby a recess 146 is formed therebetween. Thin
region 150 has formed therein passages or holes 147 (only one is
numbered) for receiving long cones 142. Passages 147 may pass all
the way through thin region 150. Square holes 148 are formed in
thin region 150 for receiving squared cones 144. Thick region 149
may have passages or holes 151 (only one is numbered) to improve
the resiliency of that region; in an alternative embodiment, thick
region 149 is formed without holes to result in a stiffer pad.
Passages 147 may be sized to provide a friction or interference fit
with long cones 142 such that long cones 142 fit snugly within
passages 147. Pad 145 may be made of slow-recovery EVA having a
hardness of 50 Shore "C", or other foam or cushioning material
suitable for the desired application. Pad 145 is molded to have a
contoured outer surface 152 that nests within the inner surface of
shell 10.
[0170] As shown in FIGS. 36-37, element 140 and pad 145 are
assembled to form front pad assembly 153. TPU element 140 is
received in recess 146, long cones 142 are received in passages
147, and the flat ends of short cones 143 abut the surface of thin
region 150. As best seen in FIG. 37, in a preferred embodiment,
long cones 142 extend through passages 147 such that the flat ends
of long cones 142 form a substantially continuous surface with pad
outer surface 152. The ends of squared cones 144 and the attached
T-nuts are also exposed at surface 152 for attachment of assembly
153 at the inner surface of shell 10. In a preferred embodiment,
pad assembly 153 is enclosed in an envelope consisting of a soft
comfort pad 154 on the side of the pad facing the wearer, and a
fabric backing 155 made of a material such as tricot on the side
facing the inner surface of shell 10. It will be appreciated that
the flat ends of long cones 142 contact the inner surface of shell
10, or have only the thin fabric layer 155 between the flat ends
and the inner surface. This composite structure provides an area of
reinforced shock absorption just above the front edge of shell 10,
coinciding with the assembly of thin region 150 and TPU element
140, while higher up, the un-reinforced thick region 149 performs
similarly to a conventional EVA brow pad. Thus, the subject
technology may include a composite front pad, comprising a molded
TPU shock absorber having frusto-conical projections extending from
a base sheet, mated with a pad of molded foam material, the
frusto-conical projections being received snugly into openings
formed in the pad of molded foam material, the mated assembly
fitted with a soft padded comfort layer. The composite front pad is
especially well suited for use in protecting against the most
forceful and frequent blows sustained in a full-contact sport, such
as the blows received on the brow of a football helmet.
[0171] FIG. 40 shows a view of a lateral assembly of TPU shock
absorbing elements that may be installed in the helmet 1 of the
subject technology, in the rear area of the helmet, and extending
to the left and right side areas of the helmet. FIGS. 41-43 show
views of the central element of the assembly. FIGS. 44-45 show
views of a top element of the assembly. FIGS. 62-63 show views of a
left wing of the assembly. FIGS. 49-51 show views of a right wing
of the assembly.
[0172] Turning first to FIG. 40, lateral TPU assembly 170 is
composed of central TPU element 171, upper TPU element 172, right
TPU element 173, and left TPU element 174. Elements 171, 172, 173,
174 may be formed integrally, or formed separately and attached
together. When formed integrally, elements 171, 172, 173, 174 may
be attached by living hinges of TPU material formed in the base
sheet. When formed separately, each of elements 171, 172, 173, 174
may be formed with a tab at the periphery for bonding to
corresponding tab of the neighboring element. The tabs may be
bonded by any suitable means known to the art, including adhesives
and plastic welding. Central TPU element 171 is connected to upper
TPU element 172, right TPU element 173, and left TPU element 174,
as shown.
[0173] Each of elements 171, 172, 173, 174 is generally similar in
construction, in that each is formed of a TPU base sheet 176, 177,
178, 179, respectively, having hollow frusto-conical projections
extending therefrom to provide shock absorption, 180, 181, 182,
183, respectively, (only one projection is numbered in each
element). One or more of these TPU elements may be formed with a
fence of TPU material, composed of base sheet material and running
along one or more edges of the elements. In the embodiment of FIGS.
40-51, central TPU element 171, right TPU element 173, and left TPU
element 174 each has such a fence of TPU material, numbered
respectively 184, 185, 186, formed along the edges which face
toward the open bottom of shell 1. Central TPU element 171 may be
formed with keyway 187 for passage of a valve for an inflatable
liner as hereinafter described. Central TPU element 171 may be
composed of a central middle portion 190, a central right lobe 188,
and central left lobe 189, integrally formed out of a single piece
of TPU material. Central right lobe 188 and central left lobe 189
are each connected to central middle portion 190 by a bridge of
base sheet material. Each of elements 171, 172, 173, 174 may have
one or more squared hollow projections 191 with a T-nut at the
distal end for attachment to the inner surface of shell 10.
[0174] FIGS. 102-104 show views of a TPU shock absorbing element
having a dense distribution of cones, which may be used in a top
area of helmet 1.
[0175] FIG. 16 shows a schematic rendering of TPU shock absorbing
elements as hereinabove described installed on the inner surface of
shell 10.
[0176] The inner padding elements of helmet 1 may include
inflatable elements, which are particularly well adapted to
custom-size helmet 1 to the wearer. In general construction,
inflatable elements according to the subject technology are formed
of bottom sheet and a top sheet of suitable material which may be
TPU material. Recesses or pockets are formed in the top sheet. The
recesses or pockets may contain pads; however, some recesses may be
devoid of pads. The bottom sheet is bonded to the top sheet to seal
the recesses or pockets and thereby form pressure-containing cells,
which may be pressurized through a valve in fluid communication
with the cells. Each of these inflatable elements or liners is
inflated through a valve disposed in a tube, the tube extending
through openings in the associated mobility layer, associated TPU
shock absorbing element, and shell, so that the liners are
inflatable from outside of helmet 1. FIGS. 55-59 show views of an
inflatable lateral liner which may be used in helmet 1, which is
installed in the rear area of the helmet and extends laterally left
and right. FIGS. 74-75 show views of an inflatable crown liner
which may be used in helmet 1, which is installed in the crown area
of the helmet. FIGS. 99-101 show plan views of pads of resilient
polymer foam material which may be disposed in the inflatable cells
of the crown inflatable liner, having shapes which conform to the
shapes of the respective cells.
[0177] Turning now to FIGS. 55-60, inflatable lateral liner 200
comprises a top sheet 201 of a suitable thin, flexible material
such as TPU, vinyl, or the like, bonded to a bottom sheet 202 of
such material. The overall liner 200 is sized and shaped to
approximately overlie lateral TPU assembly 170. Pockets are formed
in the top sheet 201, which when bonded to the bottom sheet 202
form air-containing cells 203, 204 (only one of each is numbered)
in the liner 200. Cells 203, 204, are distributed over the area of
the top sheet 201 facing the wearer, to provide comfort and shock
absorption. Certain of the cells are inflatable, and are linked
together by air-conducting passages 212 (only four are numbered) to
permit passage of inflating air into the inflatable cells.
Optionally, certain cells are non-inflatable and are not connected
by passages. In a preferred embodiment, the non-inflatable cells
are arranged at the top edge of liner 200 (i.e. the edge in the
direction of the crown of helmet 1). Cells 203, 204, are preferably
shaped so that they interlock as shown. In the illustrated
embodiment, cells 203 are shaped as truncated triangles with
concave sides, and cells 204 are crescent-shaped, thus enabling
interlocking of the cells as shown. Other interlocking shapes, or
non-interlocking shapes, could be used for the cells of liner 200.
A valve assembly 205 is connected in fluid communication with one
of the inflatable cells of liner 200 via inflation tube 206. Tube
206 passes through an opening in bottom sheet 202 to enable
inflation of the cell to which it is connected, and the entire set
of inflatable cells which are interconnected by passages 206. The
opening is sealed around tube 206 for airtightness and to anchor
tube 206 to bottom sheet 202. Liner 200 may be formed with a tab
207 having a hook-and-loop fastener 208 on top sheet 201. When
liner 200 is installed, tab 207 is tucked behind lateral TPU
assembly 170 and fastener 208 is mated with the opposite
hook-and-loop fastener adhered to the inner surface of shell 10.
Preferably, valve assembly 205 consists of valve 211, which may be
a conventional needle-inflation valve, positioned within a mating
tube 210. Mating tube 210 is mated to the distal end of inflation
tube 206, and has a flange, which is covered on the shell-facing
side with hook-and-loop fastener material. When installed, the
distal end of mating tube 210 is inserted into a through-going hole
in shell 10, and the flange is removably attached via its
hook-and-loop fastener material to the opposite hook-and-loop
fastener adhered adjacent to the through-going hole.
[0178] Turning now to FIGS. 74-75, inflatable crown liner 240 is
similar in construction to inflatable lateral liner 200. Inflatable
crown liner 240 comprises a top sheet 241 of a suitable thin,
flexible material such as TPU, vinyl, or the like, bonded to a
bottom sheet 242 of such material. The overall liner 240 is sized
and shaped to approximately overlie crown TPU element 160. Pockets
are formed in the top sheet 241, which when bonded to the bottom
sheet 242 form air-containing cells 243, 244, 252 (only one of each
is numbered) in the liner 240. Cells 243, 244, 252, are distributed
over the area of the top sheet 241 facing the wearer, to provide
comfort and shock absorption. Certain of the cells are inflatable,
and are linked together by air-conducting passages 246 (only two
are numbered) to permit passage of inflating air into the
inflatable cells. In the embodiment shown, all cells of liner 240
are inflatable. Optionally, certain cells are non-inflatable and
are not connected by passages. Cells 243, 244, are preferably
shaped so that they interlock as shown. In the illustrated
embodiment, cells 243 are shaped as truncated triangles with
concave sides, cells 244 are crescent-shaped, and cell 252 is
circular, thus enabling interlocking of the cells as shown. Other
interlocking shapes, or non-interlocking shapes, could be used for
the cells of liner 240. A valve assembly 245 is connected in fluid
communication with one of the inflatable cells of liner 240 via
inflation tube 247. Tube 247 passes through an opening in bottom
sheet 242 to enable inflation of the cell 252 to which it is
connected, and the entire set of inflatable cells which are
interconnected by passages 246. The opening is sealed around tube
246 for airtightness and to anchor tube 247 to bottom sheet 242.
Preferably, valve assembly 245 consists of valve 251, which may be
a conventional needle-inflation valve, positioned within a mating
tube 250. Mating tube 250 is mated to the distal end of inflation
tube 247, and has an integral flange, which is covered on the
shell-facing side with hook-and-loop fastener material. When
installed, the distal end of mating tube 250 is inserted into a
through-going hole in shell 10, and the flange is removably
attached via its hook-and-loop fastener material to the opposite
hook-and-loop fastener adhered adjacent to the through-going
hole.
[0179] FIGS. 10-13 show a helmet 1 according to an embodiment of
the present technology. FIGS. 10 and 13 show the placement of TPU
shock absorbing elements and cheek supports, without the mobility
layers and inflatable elements of the present technology (all of
which are hereinafter described).
[0180] In addition to the TPU shock absorbing elements, the inner
padding elements of helmet 1 may include mobility layers (also
referred to as mobility liners) disposed between the inflatable
liner elements and the TPU shock absorbing elements. Mobility
layers according to the present technology may be composed of
ethylene-vinyl acetate (EVA) polymer or a similar resilient
polymer, with a backing of black loop fabric to mate with hook pads
in a hook-and-loop fashion, the hook pads disposed on the other
liner elements to removably attach the layers to said elements and
within helmet 1. FIGS. 52-54 show views of a lateral mobility layer
that is shaped and sized to be interposed between the lateral
assembly of TPU shock absorbing elements and the lateral inflatable
liner. FIGS. 71-73 show views of a crown mobility layer that is
shaped and sized to be interposed between the the crown shock
absorbing element and the crown inflatable liner. A mobility layer
according to the subject technology incorporates bumps or domes on
the side facing the TPU shock absorbing element or elements to
reduce the area of contact and thereby reduce frictional forces
between the mobility layers and the TPU shock absorbing elements.
Alternatively, the bumps or domes could be disposed on the side
facing the inflatable liner elements, or could be disposed on both
sides of the mobility layer facing both the shock absorbing
elements and inflatable liner elements. The interposition of the
mobility layers between the TPU shock absorbing elements and the
inflatable liner elements permits relative movement between the TPU
shock absorbing elements and the inflatable liner elements when a
shock force or blow is received on the helmet during sports play,
which assists in protecting the head from being subjected to forces
and from being accelerated by said forces. In this manner, the
helmet shell 10 and attached TPU shock absorbing elements can move
to some extent in a rotational or sliding direction without
imparting the same amount or degree of movement to the inflatable
liner elements and the wearer's head, which is in contact with the
inflatable liner elements.
[0181] Turning now to FIGS. 52-54, for improved performance, a
lateral mobility layer or lateral mobility layer 220 is provided,
to be disposed or sandwiched between liner 200 and lateral TPU
assembly 170. Lateral mobility layer 220 is molded from a suitable
material, for example, EVA polymer. Mobility layer 220 is molded to
have domes 221 (only one is numbered) distributed over one side of
the liner and rising above the surface 224 of that side; the other
side is backed with a fabric covering 222. A through-going hole 223
is formed in layer 220 to allow passage of valve assembly 205 and
inflation tube 206. Mobility layer 220 is sized and shaped to
approximately overlie lateral TPU assembly 170. The domed side of
liner 220 has adhered to it hook-and-loop fastener pads 225 (only
one is shown), which preferably are sparsely distributed.
[0182] As shown in FIGS. 61-62, mobility layer 220 is assembled to
inflatable lateral liner 200 by mating fasteners 209 on bottom
sheet 202 of liner 200 with fabric cover 222 of liner 220. When
assembled, domes 221 face away from liner 200 (best seen in FIG.
62).
[0183] As best seen in FIGS. 63-64, the assembly of lateral liner
200, mobility layer 220, and lateral TPU assembly 170 results in a
sandwich of mobility layer 220 between lateral liner 200 and
lateral TPU assembly 170. Domes 221 of mobility layer 220 face
toward and contact lateral TPU assembly 170 and provide a gap or
clearance between the surface 224 of mobility layer 220 and the
elements of lateral TPU assembly 170. The domes 221 thereby reduce
the contact area between surface 224 and lateral TPU assembly 170,
and thereby reduce the transmission of rotational or sliding force
and movement of shell 10 and its attached lateral TPU assembly 170
to mobility layer 220 and lateral liner 200.
[0184] Turning now to FIGS. 72-73, according to the subject
technology, a crown mobility layer or crown mobility layer 260 is
provided, to be disposed or sandwiched between crown inflatable
liner 240 and crown TPU element 160. Crown mobility layer 260 is
similar in form to lateral mobility layer 220 and is molded from a
suitable material, for example, EVA polymer. Mobility layer 260 is
molded to have domes 261 (only one is numbered) distributed over
one side of the liner and rising above the surface 264 of that
side; the other side is backed with a fabric covering 262. A
through-going hole or cutaway 263 is formed in layer 260 to allow
passage of valve assembly 245 and inflation tube 247. Mobility
layer 260 is sized and shaped to approximately overlie crown TPU
element 160. The domed side of liner 260 has adhered to it
hook-and-loop fastener pads 265 (only one is numbered), which
preferably are sparsely distributed. Holes 266 may also be provided
in liner 260 to provide access to the T-nuts affixing crown TPU
element 160 to shell 10.
[0185] FIGS. 76-77 show views of the assembly of the crown
inflatable liner 240, crown mobility layer 260, and crown TPU shock
absorbing element 160. The inflation tube 247 of the crown
inflatable liner 240 extends through openings in the crown mobility
layer and crown TPU element 160 (through keyway 165) and is
retained by keyway retaining projections 166. A valve assembly is
assembled to the end of the tube, including an annular rim lined
with hook-and-loop material for securing the valve assembly to the
inner surface of shell 10, so the valve remains in its place at an
opening in shell 10 for inflation.
[0186] Turning now to FIGS. 99-101, the cells of lateral inflatable
liner 200 and crown inflatable liner 240 may contain pads of foam
material, for example, Omalon foam, to provide additional
cushioning performance. Preferably, the pads are shaped to fit
their cells, for example, pad 230 for crescent cells 204, 244; pad
231 for circular cell 252; and pad 232 for triangular cells 203,
243.
[0187] A face guard 150 may be removably attached to shell 10. Face
guard 150 may be in the form of a cage of metal wire, titanium
wire, steel wire, or aluminum wire, and which may be coated overall
with a polymer coating. FIGS. 105-128 show front and left-side
views of various face guard designs which may be used in helmet 1
according to the subject technology, according to the wearer's
needs and playing position.
[0188] Face guard 150 may be attached above front edge 29 of shell
10 by a twist-release mount such as that disclosed in U.S. Pat. No.
8,146,178, or in U.S. patent application Ser. No. 29/616,447, the
entire disclosure of both of which are hereby incorporated by
reference, both of which are assigned to the assignee of the
present application. FIGS. 78-82 show views of a twist-release
mount which may be used in helmet 1.
[0189] Face guard 150 may be attached to shell 10 at the left edge
30 and right edge 31 by conventional loop straps attached to shell
10 with screws, bolts, or T-nuts. The loop straps may be attached
to shell 10 with a partial-turn faceguard mounting such as those
disclosed in U.S. Pat. No. 8,819,871 for "Helmet with partial turn
faceguard mounting," the entire disclosure of which is hereby
incorporated by reference, which is assigned to the assignee of the
present application. Alternatively, in place of conventional loop
straps, face guard retainers may be used, such as those disclosed
in co-pending U.S. patent application Ser. No. 15/380,508 for
"Improved Helmet Faceguard Retaining Device," the entire disclosure
of which is hereby incorporated by reference, which is assigned to
the assignee of the present application.
[0190] While specific embodiments of the invention have been shown
and described in detail to illustrate the application of the
principles of the invention, it will be understood that the
invention may be embodied otherwise without departing from such
principles. It will also be understood that the present invention
includes any combination of the features and elements disclosed
herein and any combination of equivalent features. The exemplary
embodiments shown herein are presented for the purposes of
illustration only and are not meant to limit the scope of the
invention.
* * * * *