U.S. patent application number 17/062121 was filed with the patent office on 2021-03-25 for protective helmet.
The applicant listed for this patent is VPG AcquisitionCo, LLC. Invention is credited to Mike CZERSKI, Bob DOWNS, Brendan KAYS, Roger LEVESQUE, Brian LEWIS-CLARK, Jason NEUBAUER, Cord SANTIAGO.
Application Number | 20210085011 17/062121 |
Document ID | / |
Family ID | 1000005263123 |
Filed Date | 2021-03-25 |
![](/patent/app/20210085011/US20210085011A1-20210325-D00000.TIF)
![](/patent/app/20210085011/US20210085011A1-20210325-D00001.TIF)
![](/patent/app/20210085011/US20210085011A1-20210325-D00002.TIF)
![](/patent/app/20210085011/US20210085011A1-20210325-D00003.TIF)
![](/patent/app/20210085011/US20210085011A1-20210325-D00004.TIF)
![](/patent/app/20210085011/US20210085011A1-20210325-D00005.TIF)
![](/patent/app/20210085011/US20210085011A1-20210325-D00006.TIF)
![](/patent/app/20210085011/US20210085011A1-20210325-D00007.TIF)
![](/patent/app/20210085011/US20210085011A1-20210325-D00008.TIF)
![](/patent/app/20210085011/US20210085011A1-20210325-D00009.TIF)
![](/patent/app/20210085011/US20210085011A1-20210325-D00010.TIF)
View All Diagrams
United States Patent
Application |
20210085011 |
Kind Code |
A1 |
SANTIAGO; Cord ; et
al. |
March 25, 2021 |
Protective Helmet
Abstract
The protective helmet may comprise a flexible protective helmet
that includes a plurality of impact zones that could be
particularized to a specific occupation, sport, player-position
and/or the individual behavior of a specific player. The protective
helmet comprising a plurality of impact mitigation pads coupled to
a flexible liner may easily conform to a head of wearer. The
different embodiments comprise elements to provide a padded
protective helmet that is flexible or semi-flexible, light-weight
and adapted to reduce the risk of head trauma due to the
multi-layered padded configuration.
Inventors: |
SANTIAGO; Cord; (Seattle,
WA) ; LEWIS-CLARK; Brian; (Seattle, WA) ;
CZERSKI; Mike; (Seattle, WA) ; LEVESQUE; Roger;
(Seattle, WA) ; NEUBAUER; Jason; (Seattle, WA)
; KAYS; Brendan; (Seattle, WA) ; DOWNS; Bob;
(Seattle, WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
VPG AcquisitionCo, LLC |
New York |
NY |
US |
|
|
Family ID: |
1000005263123 |
Appl. No.: |
17/062121 |
Filed: |
October 2, 2020 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
PCT/US2019/025450 |
Apr 2, 2019 |
|
|
|
17062121 |
|
|
|
|
62735580 |
Sep 24, 2018 |
|
|
|
62651338 |
Apr 2, 2018 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A42B 3/069 20130101;
A42B 3/125 20130101 |
International
Class: |
A42B 3/06 20060101
A42B003/06; A42B 3/12 20060101 A42B003/12 |
Claims
1. An impact mitigation structure comprising: a plurality of spaced
apart elongated walls, each of the plurality of elongated walls
having a wall height and a undulated pattern, each of the plurality
of elongated walls having a cross-sectional shape, the
cross-sectional shape including a first lower portion and a second
upper portion, the first lower portion comprising a base having a
cross-sectional base width and a base height, the second upper
portion comprising an upwardly extending longitudinal member, the
upwardly extending longitudinal member extending generally
perpendicular from the base and having a cross-sectional
longitudinal member width and a longitudinal member height, the
base width is greater than the longitudinal width and the base
height is less than the longitudinal member height; and at least
one support member, the at least one support member extending
perpendicular from at least a portion of a length of the plurality
of spaced apart elongated walls.
2. The impact mitigation structure of claim 1, wherein the
undulated pattern comprises a zig-zag pattern, a herringbone
pattern, or a chevron pattern.
3. The impact mitigation structure of claim 1, wherein the impact
mitigation structure further comprises a border, the border having
a border height, the border surrounding the perimeter of the
plurality of spaced part elongated walls, the border height is at
least a portion of the elongated wall height.
4. The impact mitigation structure of claim 1, wherein each of the
plurality of elongated walls having a uniform or non-uniform wall
height.
5. The impact mitigation structure of claim 1, wherein each of the
plurality of elongated walls having an aspect ratio between 3:1 to
1,000:1.
6. The impact mitigation structure of claim 5, wherein each of the
plurality of elongated walls having an aspect ratio between 3:1 to
1,000:1 buckles after an impact, the buckling being a sudden
lateral deflection of a portion of the plurality of elongated
walls.
7. An impact mitigation pad comprising: a base material layer, the
base material layer having a first surface and a second surface, a
recess disposed onto a first surface extending towards the second
surface; and an impact mitigation structure, the impact mitigation
structure comprising a plurality of spaced apart elongated walls,
the plurality of spaced apart walls disposed within the recess, the
recess having a recess height, each of the plurality of elongated
walls having an elongated wall height, an elongated wall width and
a undulated pattern, each of the plurality of elongated walls
having a cross-sectional shape.
8. The impact mitigation pad of claim 7, wherein the undulated
pattern comprises a zig-zag pattern, a herringbone pattern, or a
chevron pattern.
9. The impact mitigation pad of claim 7, wherein each of the
plurality of elongated walls having a uniform or non-uniform wall
height.
10. The impact mitigation pad of claim 7, wherein each of the
plurality of elongated walls having an aspect ratio between 3:1 to
1,000:1.
11. The impact mitigation pad of claim 7, wherein the impact
mitigation pad further comprises a first material layer and a
second material layer.
12. The impact mitigation pad of claim 7, wherein the elongated
wall height is equal to, less than or greater than the recess
height.
13. A helmet comprising: a liner, the liner having an external
surface and an internal surface; and a plurality of impact pads, at
least a portion of the plurality of impact pads comprising base
material layer, an impact mitigation structure, a first material
layer and a second material layer, the base material layer having a
first surface and a second surface, a recess disposed onto a first
surface extending towards the second surface, the impact mitigation
structure comprising a plurality of spaced apart elongated walls,
the plurality of spaced apart walls disposed within the recess, the
recess having a recess height, each of the plurality of elongated
walls having an elongated wall height, an elongated wall width and
a undulated pattern, each of the plurality of elongated walls
having a cross-sectional shape, the plurality of impact pads being
coupled to the liner external surface.
15. The helmet of claim 13, wherein the undulated pattern comprises
a zig-zag pattern, a herringbone pattern, or a chevron pattern.
16. The helmet of claim 13, wherein each of the plurality of
elongated walls having a uniform or non-uniform wall height.
17. The helmet of claim 13, wherein each of the plurality of
elongated walls having an aspect ratio between 3:1 to 1,000:1.
18. The helmet of claim 13, wherein the impact mitigation pad
further comprises a first material layer and a second material
layer.
19. The helmet of claim 13, wherein the elongated wall height is
equal to, less than or greater than the recess height.
20. The helmet of claim 19, wherein the first material layer or the
second material layer comprises a foam layer or a polycarbonate
material.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority of Patent Cooperation
Treaty Application Serial No. PCT/US2019/025450, entitled
"Protective Helmet," filed Apr. 2, 2019 which claims benefit from
Prov. Appl. No. 62/735,580 entitled "Soft Shell Helmet," filed Sep.
24, 2018, and Prov. Appl. No. 62/651,338 entitled "Soft Shell
Helmet, filed on Apr. 2, 2018, the disclosures of which are each
incorporated by reference herein in their entireties.
TECHNICAL FIELD
[0002] The present invention relates to devices and methods for
optimizing a protective helmet or other item of protective clothing
with various impact and/or protection zones, some or all of which
incorporate flexible, pliable and/or "softer" protective features
that, in various embodiments, could be particularized to a specific
sport, player-position and/or the individual behavior of a specific
player. More specifically, the present invention relates to devices
and methods that can be utilized to protect an athlete or other
individual from a variety of incidental impacts (i.e., hitting
another player and/or having their head strike the ground or goal
post) as well as single and/or repetitive head impacts from
relatively high speed, "lighter" objects during sports such as
footballs, lacrosse balls, softballs, soccer balls, basketballs,
baseballs, field hockey pucks, rugby balls, jai alai balls and/or
water polo balls.
BACKGROUND OF THE INVENTION
[0003] Many modern organized sports employ substantial "hard and/or
flexible shell" helmets that are designed to provide players with
significant head protection from intentional and/or unintentional
impacts, including substantial impacts having a significant
potential to cause traumatic brain injuries (TBI). However, many
shell helmet designs are fairly bulky and heavy, and they often
limit a player's visibility and "field awareness" when worn.
Moreover, research suggests that the protection provided by shell
helmets may result in a higher incidence of hits involving the
player's head, in that the shell helmet may cause the player to
develop a feeling of "invulnerability," possibly leading the player
to "lead with their helmet" during collisions. Furthermore, the use
of hard shell helmets may be limited in some sports (e.g., soccer,
rugby and women's lacrosse) due to the requirements and/or
traditions within the game.
[0004] Soccer (also called "football" outside of the United States
of America) is one of the world's most popular sports. Like many
athletic activities, soccer involves some risk of injury, including
head injury. While intentional contact between soccer players is
highly discouraged, head injuries in soccer can include head
collisions with another player's head, elbow, knee, or foot, as
well as injuries when the head collides into a goal post, the
ground or some other object.
[0005] A less well-known cause of head injury in soccer and other
sports is the use of the head by a player to redirect a soccer ball
in a desired direction at a desired speed, in what is typically
called a "header." Many studies have shown that "heading" a soccer
ball (or similar repetitive impacts) can cause minor cumulative
brain damage. Many soccer players who repeatedly headed the ball
during their careers have been found to have chronic changes on
their electroencephalograms (EEGs), in many ways similar to the
changes found in amateur boxers. These players were found to have
chronic mild to severe deficits in attention, concentration,
memory, and judgement. More importantly, children, who have had
significantly less exposure to heading a soccer ball that their
professional counterparts (but who do play soccer on a frequent
basis) have been found to have greater changes in their EEGs.
[0006] While hard shell-type helmets are conventionally used in
most sports which involve a risk of head injury from one or more
major impact events, such as American football, baseball, ice
hockey, lacrosse, cycling, skiing, snowboarding, kayaking,
equestrian sports, and rock climbing, such hard shell helmets can
often interfere with the "play" and/or enjoyment of a sport, such
as seriously interfering with a soccer player's ability to "head" a
ball--thus interfering with the very nature of the sport of soccer.
Thus, conventional helmets are not used in soccer, even though
there is a significant risk of head injury.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention includes the realization of a need for
a lightweight, flexible, form-fitting protective helmet for various
occupations and participants of sports and sporting activities
where a more substantial and/or heavier rigid or shell-type helmet
may be undesirable for a variety of reasons. More specifically, the
soft-shell helmet or soft helmet should provide protection for both
"ball-to-head" related impacts and "non-ball" related impacts
(e.g., head-to-head, elbow-to-head, head-to-ground, etc.). The
protective helmet or soft-shell helmet may comprise a partial head
coverage or full head coverage protection.
[0008] In at least one exemplary embodiment, a "soft" shell helmet
can include a protective headband. The protective headband can
protect at least a portion of the head. The protective headband may
comprise a tubular or generally cylindrical shape and
configuration, which desirably fits around an upper portion of the
wearer's head (i.e., across the forehead and above a portion of the
ears). The headband may comprise at least one or more padded
regions and at least one boot layer. The at least one boot layer
may comprise one single material layer or two or more material
layers. In one preferred embodiment, the at least one boot layer
may comprise at least one first material, at least one second
material, and at least one foam material and/or layer, the at least
one foam material and/or layer being affixed to the at least one
first and at least one second material. The at least one first or
at least one second material may be a two- or four-way stretch
fabric, where the top and bottom covering may be the same material
or the at least one top and bottom covering may be different
materials. The at least one or more padded regions comprising one
more individual impact pads, which can be separated by one or more
stretchable regions. In various embodiments, the stretchable
regions can comprise one or more layers of elastic material or
"two- or four-way stretch fabric," which can allow the helmet to be
expanded and/or contracted to accommodate heads of differing
shapes, sizes and/or configurations, as well as to accommodate
different wearing positions and/or styles by the player. Various
embodiments can further include lower portions for extending along
the sides, face and/or jaws of the wearer, as well as an optional
peak or domed portion for protecting the top of the wearer's head.
In various embodiments, the padded regions may protect the
forehead, temples, and the occipital bone in the back of the
wearer's head.
[0009] In one exemplary embodiment, a soft-shell helmet may
comprise a full-coverage or full-face soft-shell helmet. The
full-coverage helmet may cover the entire head, with a rear that
covers the base of the skull, and a protective section that may
cover the front of the chin and temples. Such full coverage helmets
desirably have an open cutout to allow access to the face.
[0010] The full-coverage soft-shell helmet can comprise at least
one of a boot layer or liner, at least one impact pad, at least one
optional ear cover (which may comprise a removable and/or
replaceable separate ear cover), a chinstrap, and/or any
combination thereof. The at least one boot layer may comprise one
single material or two or more materials. The at least one boot
layer may further comprise an impact mitigation layer. In one
preferred embodiment, the at least one boot layer may comprise at
least one first material, a second material, and a foam layer
material, the foam layer being affixed to the first and second
material and disposed between the first and second material. The at
least one ear cover and/or the chinstrap may be removably coupled
to the soft-shell full-coverage helmet. The at least one or more
individual impact mitigation pads may be directly affixed to the
boot layer or liner. The impact mitigation pads may be desirably
positioned on different regions of the head, including the frontal
section, top or ridge section, lower back, mid-back, left side and
front side, temples, jaw region and/or any combination thereof. The
at least one or more individual impact pads may comprise at least
one impact structure that can be affixed to the boot layer in
desired regional locations to enhance impact protection. The at
least one or more individual impact pads may further comprise a
foam layer.
[0011] In various embodiments, the soft-shell helmet may optionally
not incorporate an ear cover and/or may comprise a perforated
portion of the helmet and/or may comprise a material capable of
reasonable levels of sound transmission therethrough.
[0012] In another exemplary embodiment, the at least one or more
individual impact pads may further comprise at least one impact
structure, at least one first layer and at least one second layer.
The at least one first layer or the at least one second layer may
include a foam layer, polycarbonate layer, a hotmelt layer, a 2-way
stretch material, a 4-way stretch material, Lycra, Ducksan Power
Net, Neoprene, and/or any combination thereof. The polycarbonate
layer can be thin, flexible, yet substantially rigid to assist with
absorption of the forces and reduce wear/tear. The foam layer can
include polymeric foams, quantum foam, polyethylene foam,
polyurethane foam (PU foam rubber), XPS foam, polystyrene,
phenolic, memory foam (traditional, open cell, or gel), impact
absorbing foam, compression foam, latex rubber foam, convoluted
foam ("egg create foam"), EVA foam, VN 600 foam, Evlon foam,
Ariaprene or Ariaprene-like material, impact hardening foam, and/or
any combination thereof. The at least one foam layer may have an
open-cell structure or closed-cell structure. The foam layer can be
further tailored to obtain specific characteristics, such as
anti-static, breathable, conductive, hydrophilic, high-tensile,
high-tear, controlled elongation, and/or any combination
thereof.
[0013] In another exemplary embodiment, the at least one or more
individual impact pads may further comprise at least one impact
structure assembly, at least one first layer and at least one
second layer. Alternatively, the at least one or more individual
impact pads may further comprise at least one impact structure
assembly, at least one foam layer, at least one first layer and at
least one second layer. The impact structure assembly may comprise
a two-piece assembly that comprises an impact mitigation structure
and a first layer. The first layer may comprise a recess forming a
pocket and a flange, the pocket may be shaped and configured to
receive the impact mitigation structure, the impact mitigation
structure disposed within the pocket. The at least one second layer
may be affixed to the at least one first layer, impact mitigation
structure, at least one second layer, and/or any combination
thereof. Alternatively, the impact structure assembly may comprise
a one-piece assembly that integrates the impact mitigation
structure within the first layer. The one-piece impact mitigation
structure assembly is comprised of a first layer and an impact
mitigation structure that may be thermoformed, injection molded, 3D
printed, casted and/or die cut as a one-piece construct.
[0014] The at least one first layer and/or the at least one second
layer may comprise a single layer or multiple layers. Each of the
at least one first layer and/or the each of the at least one second
layer may comprise a 2-way stretch material, a 4-way stretch
material, a foam layer, a polycarbonate layer, a hotmelt layer, a
boot layer, Lycra, Ducksan and/or any combination thereof. The
polycarbonate layer can be thin, flexible, yet substantially rigid
to assist with absorption of the forces and reduce wear/tear. The
foam layer can include polymeric foams, quantum foam, polyethylene
foam, polyurethane foam (PU foam rubber), XPS foam, polystyrene,
phenolic, memory foam (traditional, open cell, or gel), impact
absorbing foam, latex rubber foam, convoluted foam ("egg create
foam"), EVA foam, VN600 foam, Evlon foam, Ariaprene or
Ariaprene-like material, impact hardening foam, compression and/or
any combination thereof. The at least one foam layer may have an
open-cell structure or closed-cell structure.
[0015] In one exemplary embodiment, the at least one or more
individual impact pads may be encapsulated to form pockets, where
the pockets can be affixed to the boot layer. The at least one or
more individual impact pads may comprise at least one impact
structure and/or at least one impact structure assembly, at least
one first layer, at least one second layer, and at least one top
covering or at least one bottom covering. Alternatively, the at
least one or more pocketed individual impact pads may comprise an
impact mitigation structure and/or at least one impact mitigation
structure assembly, and a least one top covering. The at least one
first layer or the at least one second layer may include a 2-way
stretch material, a 4-way stretch material, a foam layer,
polycarbonate layer, a hotmelt layer, boot layer and/or any
combination thereof. The at least one top or at least one bottom
covering may be a two- or four-way stretch fabric, where the top
and bottom covering may be the same material or the at least one
top and bottom covering may be different materials. The impact
mitigation structure may be "free-floating" and/or fixed within the
at least one top covering and/or at least one bottom covering, or
permanently secured within the at least one top and/or bottom
covering. The polycarbonate layer can be thin, flexible, yet
substantially rigid to assist with absorption of the forces and
reduce wear/tear. The foam layer can include polymeric foams,
quantum foam, polyethylene foam, polyurethane foam (PU foam
rubber), XPS foam, polystyrene, phenolic, memory foam (traditional,
open cell, or gel), impact absorbing foam, latex rubber foam,
convoluted foam ("egg create foam"), EVA foam, VN600 foam, Evlon
foam, Ariaprene or Ariaprene-like material, impact hardening foam,
compression foam, and/or any combination thereof. The at least one
foam layer may have an open-cell structure or closed-cell
structure. The foam layer can be further tailored to obtain
specific characteristics, such as anti-static, breathable,
conductive, hydrophilic, high-tensile, high-tear, controlled
elongation, and/or any combination thereof.
[0016] In various embodiments, the one or more impact pad
section(s) can comprise at least one impact structure, the at least
one impact structure can comprise at least a portion of filaments,
a portion of auxetic structures, a portion of zigzag structures, a
portion of herringbone structures, and/or laterally supported
filaments and/or wall structures. Such impact mitigation structures
may include polygonal structures and/or thin, longitudinally
extending members that may be shaped and configured to deform
non-linearly in response to an impact force, auxetic structures,
re-entrant structures, TPU cones, impact foam, and/or any
combination thereof. In various instances, a non-linear deformation
behavior of one or more of these structures is expected to provide
improved protection against high-impact forces and/or oblique
forces, as well as afford a significant level of durability,
elasticity and/or flexibility to the impact pad section(s). In
various embodiment, the impact pad section(s) can be deformable
and/or stretchable, which can include deformability in a variety of
directions, including along the cephalad/caudal, medial/lateral
and/or anterior/posterior axes of the helmet and/or the wearer, as
well as complex combinations thereof.
[0017] In various embodiments, the one or more impact pad sections
could comprise auxetic structures and/or could comprise re-entrant
shaped structures, such as bowtie shapes, and/or could comprise a
series of repeating geometric shapes or undulating structures, such
as T-shaped or chevron shapes, or various combinations thereof.
[0018] In various embodiments, a soft helmet design could be
designed and/or tailored to accommodate various types and/or
locations of forces, including factors or a combination of two or
more factors in a sport-specific and/or position-specific manner,
which could include impact protection features designed to protect
against one or more specific locations and/or types of locations
and/or degrees of impact or other forces, including (but not
limited to) source of impact, angle of impact, player activity
type, play type, player position, location of impact, angle of
impact, severity of impact, and/or frequency of impacts.
[0019] In one embodiment, an impact mitigation structure comprises
a plurality of spaced apart elongated walls, each of the plurality
of elongated walls having a wall height and a undulated pattern,
each of the plurality of elongated walls having a cross-sectional
shape, the cross-sectional shape including a first lower portion
and a second upper portion, the first lower portion comprising a
base having a cross-sectional base width and a base height, the
second upper portion comprising an upwardly extending longitudinal
member, the upwardly extending longitudinal member extending
generally perpendicular from the base and having a cross-sectional
longitudinal member width and a longitudinal member height, the
base width is greater than the longitudinal width and the base
height is less than the longitudinal member height; and at least
one support member, the at least one support member extending
perpendicular from at least a portion of a length of the plurality
of spaced apart elongated walls.
[0020] In one embodiment, an impact mitigation pad comprises a base
material layer, the base material layer having a first surface and
a second surface, a recess disposed onto a first surface extending
towards the second surface; and an impact mitigation structure, the
impact mitigation structure comprising a plurality of spaced apart
elongated walls, the plurality of spaced apart walls disposed
within the recess, the recess having a recess height, each of the
plurality of elongated walls having an elongated wall height, an
elongated wall width and a undulated pattern, each of the plurality
of elongated walls having a cross-sectional shape.
[0021] In one embodiment, the protective helmet comprises a liner,
the liner having an external surface and an internal surface; and a
plurality of impact pads, at least a portion of the plurality of
impact pads comprising base material layer, an impact mitigation
structure, a first material layer and a second material layer, the
base material layer having a first surface and a second surface, a
recess disposed onto a first surface extending towards the second
surface, the impact mitigation structure comprising a plurality of
spaced apart elongated walls, the plurality of spaced apart walls
disposed within the recess, the recess having a recess height, each
of the plurality of elongated walls having an elongated wall
height, an elongated wall width and a undulated pattern, each of
the plurality of elongated walls having a cross-sectional shape,
the plurality of impact pads being coupled to the liner external
surface.
[0022] While the various optimized soft-shell helmet components
and/or designs provided herein are depicted with respect to soccer
and/or related sports, it should be understood that the various
devices, methods and/or components may be suitable for use in
protecting players in various other athletic sports, as well as law
enforcement, military and/or informal training session uses. For
example, the embodiments of the present invention may be suitable
for use by individuals engaged in athletic activities such as
football, two hand touch football, flag football, softball, dodge
ball, baseball, bowling, boxing, cricket, cycling, motorcycling,
golf, hockey, lacrosse, soccer, rowing, rugby, running, skating,
skateboarding, skiing, snowboarding, surfing, swimming, table
tennis, tennis, or volleyball, water polo, wrestling, wakeboarding
and/or during training sessions related thereto.
[0023] Described herein are many specific embodiments, but these
should not be construed as limitations on the scope of any
inventions or of what may be claimed, but rather as descriptions of
factors specific to various implementations of the present
inventions. Certain factors described herein in the context of
separate implementations can also be implemented in a single
implementation. Conversely, various factors described in the
context of a single implementation can also be implemented in
multiple implementations separately or in any suitable sub
combination. Furthermore, the factors as described above may be
recited as acting in certain combinations and even initially
claimed as such, one or more factors from a claimed combination can
in some cases be excised from the combination, and the claimed
combination may be directed to a sub combination or variation of a
sub combination.
DETAILED DESCRIPTION OF DRAWINGS
[0024] FIG. 1 depicts an isometric view of one embodiment of a
soft-shell helmet;
[0025] FIG. 2A depicts a side view of an alternate embodiment of a
soft-shell helmet;
[0026] FIG. 2B depicts a front view of one embodiment of a boot
layer or liner;
[0027] FIG. 3A depicts a side view of the soft-shell helmet in FIG.
2A;
[0028] FIG. 3B depicts a front view of one embodiment of one or
more impact mitigation structures;
[0029] FIGS. 4A-4B depicts a top and side view of an alternate
embodiment of one or more impact mitigation structures;
[0030] FIG. 5 depicts a side and isometric view of an impact
mitigation structure that may be encapsulated in a soft shell
helmet;
[0031] FIG. 6 depicts a top view of an alternate embodiment of one
or more impact mitigation structures;
[0032] FIGS. 7A-7B depict exploded views of different embodiments
of a boot layer or liner;
[0033] FIGS. 7C-7D depict cross-sectional views of one embodiment
of a boot layer or liner;
[0034] FIGS. 8A-8C illustrate top views of different embodiments of
the one or more impact mitigation structure configurations;
[0035] FIGS. 9A-9E illustrate one embodiment of a method to
manufacture a boot layer or liner;
[0036] FIGS. 10A-10C depict cross-sectional views of one or more
impact mitigation pads or one or more impact mitigation structures
coupled to a boot layer or liner;
[0037] FIGS. 11A-11G illustrate one embodiment of a method to
manufacture one or more impact mitigation pads;
[0038] FIGS. 12A-12C illustrate one embodiment of a method to
couple the one or more impact mitigation pads to a boot layer or
liner;
[0039] FIGS. 13A-13B depict a side and front view of the soft-shell
helmet of FIG. 2A;
[0040] FIG. 13C depicts a front view of one alternative embodiment
of a covered soft-shell helmet;
[0041] FIG. 14 depicts one embodiment of an assembly of a
soft-shell helmet;
[0042] FIGS. 15A-15C depicts an alternate embodiment of a method to
couple or affix the one or more impact mitigation pads to a boot
layer or liner;
[0043] FIGS. 16A-16B depicts different embodiments of one or more
impact mitigation pads;
[0044] FIGS. 17A-17C illustrates one embodiment of a boot layer or
liner construction;
[0045] FIG. 18 depicts a front view of one embodiment of a
headband;
[0046] FIGS. 19A-19B depicts a front view of one embodiment of a
soft shell helmet with ear protection;
[0047] FIG. 20 depicts an isometric view of an alternate embodiment
of an impact structure;
[0048] FIG. 21 depicts a top view of one embodiment of an undulated
wall impact structures;
[0049] FIGS. 22A-22E depicts various views of an alternate
embodiment of a soft-shell helmet;
[0050] FIGS. 23A-23B depicts one embodiment of a front impact pad
assembly and/or a rear impact pad assembly to form a soft-shell
helmet;
[0051] FIG. 24 depicts one embodiment of a front impact pad
assembly to form a soft-shell helmet;
[0052] FIGS. 25A-25B depicts a top and bottom view of one
embodiment of one or more impact mitigation pads;
[0053] FIGS. 26A-26B depicts a front and isometric view of an
alternate embodiment of one or more impact mitigation pads;
[0054] FIGS. 27A-27B depicts an exploded view of an alternate
embodiment of one or more impact mitigation pads;
[0055] FIGS. 28A-28B depicts a side view of the one or more impact
mitigation pads of FIGS. 27A-27B coupled to a base layer or
liner;
[0056] FIGS. 29A-29F depict one embodiment of a method to
manufacture a front impact pad assembly to form a soft-shell
helmet;
[0057] FIGS. 30A-30C depict one embodiment of a method to
manufacture a back impact pad assembly to form a soft-shell
helmet;
[0058] FIGS. 31A-31C depict one embodiment of a method to couple
the front impact pad assembly with the back impact pad assembly to
form a soft-shell helmet;
[0059] FIGS. 32A-32B depict a front and side view of an alternate
embodiment of a headband;
[0060] FIGS. 33A-33D depict different views of one embodiment of a
headband construction;
[0061] FIGS. 34A-34C depicts various views of one embodiment of a
headband size and configuration on a head of wearer;
[0062] FIGS. 35A-35C depicts one embodiment of a method to
manufacture the one or more impact mitigation structures for a
headband;
[0063] FIGS. 36A-36B depicts different views of an alternate
embodiment of a headband with headband skin;
[0064] FIGS. 37A-37C depicts different views of an alternate
embodiment of a headband;
[0065] FIG. 37D depicts an exploded view of a portion of the
headband of FIGS. 37A-37C; and
[0066] FIGS. 38A-38G depicts various views of an alternate
embodiment of a soft-shell helmet.
DETAILED DESCRIPTION OF THE INVENTION
Soft Shell Helmets
[0067] The term "soft helmet" or "soft shell" should not be limited
to helmet designs that solely incorporate only soft or flexible
components, but could also include helmets or other protective
clothing designs that may incorporate harder and/or relatively
rigid, shell or plate components or similar features, including the
incorporation of flexible or sliding plates that can accommodate
stretching and/or flexing of the overlying/underlying helmet
structure(s).
[0068] In various embodiments, a soft helmet can comprise a
headband, head wrap, cap and/or full coverage helmet having one or
more impact mitigating structures disposed thereon, such as shown
in FIG. 1, FIG. 2, FIG. 13A, and/or FIG. 18. The soft helmet may
comprise at least one of a breathable and/or sweat wicking layer,
an impact mitigating structure layer, a foam layer, a boot layer
and/or any combination(s) thereof. FIGS. 1 and 19A-19B depicts an
isometric view of one embodiment of a soft helmet design. The soft
helmet 10 comprises a boot layer or liner 30 and one or more impact
mitigation pads 20. The soft helmet 10 may further comprise ear
protection 35 or a chin strap (not shown). The impact mitigation
pads 20 may be desirably affixed to an external surface of the boot
layer or liner 30 and positioned on different regions of the head,
including the frontal section, top or ridge section, lower back,
mid-back, left side, right side and front side, temples, jaw region
and/or any combination thereof. The impact mitigation pads 20 may
comprise impact mitigation structures. The impact mitigating
structures may comprise deforming filament and/or laterally
supported filaments, and/or lateral wall-based structures,
including the employment of repeating geometric patterns,
undulating structures, and/or auxetic/non-auxetic impact mitigating
structures. FIGS. 2A-2B and 3A-3B depict another exemplary
embodiment of a soft helmet 40. The soft helmet system 40
comprising a liner or boot layer 50 and an impact mitigation layer
60. The impact mitigation layer comprises one or more impact
mitigation pads or impact mitigation structures that can be affixed
to an external surface of the liner or boot layer 50. The impact
mitigating structures comprising a portion of filaments, laterally
supported filaments, undulating structures or repeating geometric
patterns, and/or auxetic wall structures.
[0069] FIGS. 3A-3B depicts one embodiment of an impact mitigation
layer 60. The impact mitigation layer 60 can comprise one or more
impact mitigation structures 90. The impact mitigation structures
90 can include "auxetic" structures, a plurality of interconnected
members forming an array of reentrant shapes positioned on the
flexible head layer. Each of the reentrant shapes may be connected
to the adjacent reentrant shape by at least one shared wall. In one
specific embodiment, impact mitigation structures 90 may comprise a
plurality of interconnected reentrant structures forming an array,
the array comprises a first reentrant shape and a second reentrant
shape, the second reentrant shape is connected perpendicular to the
first reentrant shape. Each of the first or second reentrant shape
having a length, the length provides for an ideal buckling
structure, the buckling is a sudden lateral defection away from a
longitudinal axis. The term "auxetic" generally refers to a
material or structure that has a negative Poisson ratio, when
stretched, auxetic materials or structures become thicker (as
opposed to thinner) in a direction perpendicular to the applied
force. The employment of such auxetic structures can result in a
protective device capable of high energy absorption and fracture
resistance. In particular, when a force is applied to the auxetic
material or structure, the impact may cause it to expand (or
contract) in one direction, resulting in associated expansion (or
contraction) in a perpendicular direction. It should be recognized
by those skilled in the art that the auxetic structures shown in
FIGS. 2A-2B and 3A-3B may include a wide variety of differently
shaped segments or other structural members, as well as
combinations of repeating and/or different shaped voids. The one or
more impact mitigation structures 90 can be injection molded, where
the injection molded process allows the one or more impact
mitigation structures 90 to be manufactured flat, and flexible. The
one or more impact mitigation structures 90 may be flexed to affix
to the head boot or liner 50 to conform to the complex curvature of
the head. Alternatively, the one or more impact mitigation
structures 90 may be covered by a fabric (not shown).
[0070] Accordingly, the boot layer or liner 50 may be constructed
from a single, continuous template or using two or more templates.
As shown in FIG. 2B, the boot layer or liner 50 may comprise two or
more templates 80, 90. The two or more templates 80, 90 may be
coupled together to form the boot layer or liner 50 that can be
form fitting and substantially conforms to a wearer's head. The
boot layer or liner 50 may comprise an ear aperture 70, where the
ear aperture 70 is sized and configured to fit a wearer's ear
and/or ear protection. Furthermore, the boot layer or liner 50 may
comprise one or more layers. More specifically, the boot layer or
liner 50 may comprise at least a first layer, a second layer. The
first or second layer may comprise a foam layer (e.g., EVA), a
4-way stretch material, or a 2-way stretch material. The foam layer
can include polymeric foams, quantum foam, polyethylene foam,
polyurethane foam (PU foam rubber), XPS foam, polystyrene,
phenolic, memory foam (traditional, open cell, or gel), impact
absorbing foam, compression foam, latex rubber foam, convoluted
foam ("egg create foam"), EVA foam, VN 600 foam, Evlon foam,
Ariaprene or Ariaprene-like material, impact hardening foam, and/or
any combination thereof. The at least one foam layer may have an
open-cell structure or closed-cell structure. The foam layer can be
further tailored to obtain specific characteristics, such as
anti-static, breathable, conductive, hydrophilic, high-tensile,
high-tear, controlled elongation, and/or any combination
thereof.
[0071] FIGS. 4 through 6 depict another exemplary embodiment of
impact mitigating structures comprising undulating structures 100,
including chevron-shapes, "zig-zag" and/or herringbone patterned
structures that form "V" shapes as shown in FIG. 21. In this
embodiment, FIGS. 4A-4B depict one embodiment of an undulating
impact structure 100. The undulating impact structures 100
comprises a plurality of undulating walls 110 and a plurality of
lateral support walls or support members 120, the plurality of
undulating walls 110 forming an array, each of the plurality of
undulating walls 110 having a sinusoidal shape and a height. The
plurality of lateral support walls or support members 120 can
reinforce, connect and/or support the plurality of undulating walls
110 (e.g., chevron, zig-zag or herringbone structures). Each of the
undulating structure 100 may further comprise a vertical height
130. In various embodiments, the lateral walls 120 may extend the
entire vertical height 130 of the undulating structure 100, or
undulating chevron, zig-zag or herringbone structure, while in
other embodiments the lateral walls 120 may not extend the full
vertical height of the chevron structures and/or may partially
extend substantially perpendicular along the upper, lower and/or
center portion(s) of the undulating walls 110. "Substantially" may
comprise angles of 70-110 degrees. Alternatively, the undulating
walls 110 may have different configurations, including herringbone,
chevron structures or zig-zag patterns that may comprise of lateral
walls 120 with frustum or cone-shape and/or configuration. FIG. 20
depicts one embodiment of a frustum shaped chevron patterned
lateral wall, where the lateral wall has a top surface and a bottom
surface, the top surface has tapered walls that extend from the top
surface to the bottom surface. The bottom surface may further
comprise an enlarged base or flange that extends outward from the
bottom surface. The top surface may be radiused, chamfered and/or
beveled. For example, the chevron shapes or structures may be
manufactured from materials with different durometers. Such
durometers may comprise a range from 70 Shore A to 70 Shore D.
[0072] FIGS. 5 and 6 depict one embodiment of an undulating impact
mitigation structure 100 that may be covered or uncovered. Each of
the plurality of undulating impact mitigation structure 100 may be
sized and configured to a custom shape. The custom shape may
desirably allow mirror images of the custom shape (e.g., left and
right structures) for ease of manufacturing. Each of the plurality
of undulated impact mitigation structure 100 may be affixed
directly onto the boot layer or liner or they may include a
covering to form an undulated impact mitigation pad 150. The
undulated impact mitigation pad 150 may comprise a first layer, a
second layer and an undulated impact mitigation structure 100. FIG.
6 shows one exemplary embodiment of a custom shaped undulated
impact mitigation structure 160. The custom shaped undulated impact
mitigation structure 160 may comprise a plurality of undulating
walls 180, at least one lateral support wall or support member 170,
and a border 190. The plurality of lateral support walls or support
members 170 can reinforce, connect and/or support the plurality of
undulating walls 180 (e.g., chevron, zig-zag or herringbone
structures). Each of the plurality of undulating walls 180 may
further comprise a wall height 140. In various embodiments, the
lateral walls 170 may extend the entire vertical height 200 of the
undulating structure 160, or undulating chevron, zig-zag or
herringbone structure, while in other embodiments the lateral walls
170 may not extend the full vertical height of the chevron
structures and/or may partially extend substantially perpendicular
along the upper, lower and/or center portion(s) of the undulating
walls 180. "Substantially" may comprise angles of 70-110 degrees.
Alternatively, the undulating walls 180 may have different
configurations, including herringbone, chevron structures or
zig-zag patterns that may comprise of lateral walls 170 with
frustum or cone-shape and/or configuration. The border 190 may
surround at least a portion or the entire plurality of undulating
walls 180. The undulating wall height 140 may comprise an elongated
height that facilitates a buckling deformation, the buckling being
a sudden lateral deflection away from each of the plurality of
undulating wall 180 longitudinal axis.
[0073] In various embodiment, the impact mitigation structures can
range in size or wall height 140 from 1 to 20 mm thick, and may
incorporate different thicknesses of structure(s) throughout one
single impact mitigation pad and/or pad assembly, and among the
several impact mitigation pads and/or pad assemblies in the soft
shell helmet, to desirably accommodate different frequencies, types
and/or magnitudes of impact anticipated for the wearer. Such design
can be sport and/or player specific, including various designs for
sports such as soccer, etc.
[0074] In various additional embodiments, the impact mitigating
structures may comprise filaments (longitudinally extending members
that deform non-linearly in response to an impact source),
polygonal structures (in an array or segmented), single-layered
impact layers or multi-layered impact layers, and/or any
combination thereof. Furthermore, the impact mitigating structures
may be provided in a continuous array or a segmented array. The
thin, longitudinally extending members may be shaped and configured
to deform non-linearly in response to an impact force. The
non-linear deformation behavior is expected to provide improved
protection against high-impact forces, and/or oblique forces. The
non-linear deformation behavior can be described by at least a
portion of the filament's individual and/or en-masse stress-strain
profile. The non-linear stress-strain profile can illustrate that
there is an initial rapid increase in resistance to an impact
force, followed by a change in slope that may be flat, decreasing
or increasing slope, followed by a third region with a different
slope.
[0075] If desired, the impact mitigating structures can comprise
laterally supported filaments. The impact mitigating structures can
comprise at least a portion of a plurality of filaments that are
interconnected by laterally positioned walls or sheets in a
polygonal configuration. At least a portion of the filaments
arranged in a hexagonal pattern interconnected by laterally
positioned walls. Alternatively, other polygonal structures known
in the art may be contemplated, such as triangular, square,
pentagonal, hexagonal, septagonal, octagonal, etc. A plurality of
sheets or lateral walls can be secured between adjacent pairs of
filaments with each filament having a pair of lateral walls
attached thereto. In the disclosed embodiment, the lateral walls
can be oriented approximately 120 degrees apart about the filament
axis, with each lateral wall extending substantially along the
longitudinal length of the filament. Alternatively, the hexagonal
pattern may allow at least one lateral wall to be asymmetric, which
the angle of the wall may be between 90 to 135 degrees. The shape,
wall thickness or diameter, height, and configuration of the
lateral walls and/or filaments may vary to "tune" or "tailor" the
structures to a desired performance. For example, one embodiment of
a hexagonal structure may have a tapered configuration. The
hexagonal structure can have a top surface and a bottom surface,
with the bottom surface perimeter (and/or bottom surface
thickness/diameter of the individual elements) may be larger than
the corresponding top surface perimeter (and/or individual element
thickness/diameter). In another example, the hexagonal structure
can have an upper ridge. The upper ridge can also facilitate
connection to another structure, such as an inner surface of a
helmet, an item of protective clothing, and/or a mechanical
connection (e.g., a grommet or plug having an enlarged tip that is
desirably slightly larger than the opening in the upper ridge of
the hexagonal element).
[0076] Desirably, at least a portion of the elements in the impact
mitigating structures will desirably buckle and/or deform in
response to an incident force, where buckling may be characterized
by a localized, sudden failure of the filament structure subjected
to high compressive stress, where the actual compressive stress at
the point of failure is less than the ultimate compressive stress
that the material is capable of withstanding. Furthermore, the at
least a portion of the filaments may be configured to deform
elastically, allowing the at least a portion of the filaments to
substantially return to their initial configuration once the
external force is removed.
[0077] Furthermore, the polygonal or hexagonal structures may be
manufactured as individual structures. The manufacturing individual
polygonal or hexagonal structures may include extrusion, investment
casting or injection molding process. Each individual polygonal or
hexagonal structure may be affixed directly to the inner or outer
surface of the helmet outer layer, inner or outer surface of the
helmet inner layer, the inner or outer surface of the helmet impact
absorbing layer, and/or any combination thereof. Also, they may
have the same shape and configuration with repeating symmetrical
arrangement or asymmetrical arrangement and/or different shape and
configurations with repeating symmetrical arrangement or
asymmetrical arrangement.
[0078] Conversely, the polygonal or hexagonal structures may be
manufactured directly into a patterned array affixed to at least
one base material. The base material may be manufactured with a
polymeric or foam material. The polymeric or foam material may be
elastic to allow it to be easily bent, twisted or flexed to conform
to complex surfaces. Alternatively, the polymeric and/or foam
material may be substantially rigid. The manufacturing of each
patterned array of polygonal or hexagonal structures may include
extrusion, investment casting or injection molding process. Each
patterned array of polygonal or hexagonal structure and/or the base
material may be affixed directly to the liner.
[0079] If desired, a regional location and/or distribution of the
segmented arrays on the boot layer may be positioned to accommodate
a desired "position-specific" purpose. In various embodiments, the
segmented arrays may include regionally specific arrays, such as
the front, jaw, midline (surrounding the majority of the
circumference to include right side, mid-back and left side), top,
lower back layer 1 and lower back layer 2.
[0080] The impact mitigating structures may be bonded or coupled
directly to a boot layer or liner. The impact mitigating structures
and the boot layer may further comprise at least one top covering
and one bottom covering. The at least one top covering and at least
one bottom covering may comprise a resilient fabric that may
include a two-way or four-way stretch material, any elastic
material, a soft-flexible material, and/or any combination thereof.
The at least one top covering and at least one bottom covering may
be the same material, or they may be different materials. The
impact mitigating structures and the boot layer may be coupled to a
foam layer or other layer. Such coupling may be accomplished by
using adhesives, molding, heat and/or material welding, sintering
or any other method known in the art. The foam layer may comprise a
single layer or multiple layers, which any of the layers may be
comprised of various types of foam, such as TPU foam, Poron XRD
foam, impact resistant foam, compression foam, and/or any
combination thereof. All of the segmented impact mitigating
structures may be coupled to the base layer or at least a portion
of the segmented impact mitigating structures may be coupled to the
base layer. Alternatively, the impact mitigating structures may be
"free-floating" within the base layer. The base layer can be
coupled around the complete perimeter of the impact mitigating
structure completely enclosing the impact mitigation structure, but
still allowing the impact mitigation structure to "freely-float"
and/or be fixed within the base layer. In addition, the base layer
can be coupled around at least a portion of the perimeter of the
impact mitigating structure leaving an opening, such that the
impact mitigation structure "freely-floats" within base layer. The
opening may be sized and configured to allow the impact mitigation
structure to be removably coupled within the base layer, and easy
replacement of the impact mitigation structure. The opening may be
closed using various mechanical methods known in the art, including
stitching, snaps, Velcro, magnets, and/or any combination
thereof.
[0081] In various embodiments, each of the individual impact
mitigating structures or patterned arrays of mitigating structures
may be have at least one covering to form individual pads, pad
assemblies or pad arrays. The at least one covering may be a
loosely or tightly woven fabric. The fabric may be polymeric, such
as polypropylene, polyethylene, polyester, nylon, PVC, PTFE, and/or
any combination thereof. The fabric may be 2-way or 4-way stretch
material. Furthermore, the at least one covering may be breathable
and wick away moisture easily from the skin while carrying out
various sporting and athletic activities. For example, the covering
may completely or continually cover an entire array of impact
mitigating structures (not shown). Conversely, the covering may
cover at least a portion of an entire array of impact mitigating
structures. Furthermore, the covering may cover segmented arrays of
impact mitigating structures or individual impact mitigating
structures.
[0082] In various embodiments, each of the individual impact
mitigating structures or patterned array of mitigating structures
may have at least one foam layer. The at least one foam layer can
include polymeric foams, quantum foam, polyethylene foam,
polyurethane foam (foam rubber), XPS foam, polystyrene, phenolic,
memory foam (traditional, open cell, or gel), impact absorbing
foam, compression foam, latex rubber foam, convoluted foam ("egg
create foam"), EVA foam, VN600, Evlon foam, impact hardening foam,
and/or any combination thereof. The at least one foam layer may
have an open-cell structure or closed-cell structure. The at least
one foam layer can be further tailored to obtain specific
characteristics, such as anti-static, breathable, conductive,
hydrophilic, high-tensile, high-tear, controlled elongation, and/or
any combination thereof.
[0083] One particularly advantageous feature of the designs
described herein is the ability to mold and/or assemble the impact
layer and various other helmet components in a flat plane, which
can make the tool design and construction much easier. For the best
possible fit on all different head shapes, an ideal material to
wrap the head with is a four way stretch material or a material
that can stretch in all directions, and the impact mitigating
structures can be attached to this type of a material and, due to
the unique design, can flex and take shape over a complex contoured
shape without wrinkles. Finally, the walled impact structure allows
for an impact protective layer that easily allows for moisture
vapor to pass thru, allowing the users head to naturally cool when
wearing, unlike other impact layers that limit this ability.
[0084] For example, FIGS. 7A-7B depicts different exemplary
embodiments of a helmet "boot layer," "boot" construction or
"liner". FIGS. 7C-7D depicts one embodiment of a boot layer or
liner 230, the boot layer or liner 230 may comprise at least one
single material layer or a plurality of material layers. Each of
the plurality of layers may be manufactured to accommodate and
protect the desired region of the player's head. The desired
regions may include the front, upper sides (right and left) lower
sides (right and left), ridge (top of head), mid back, lower back,
jaw, temples, and/or any combination thereof. The boot layer may
comprise one material layer. Alternatively, the boot layer or liner
230 may comprise at least one first material 240 and at least one
second material 260. In one preferred embodiment, the boot layer or
liner 230 may comprise at least one of a first material 240, at
least one second material 260, and at least one foam layer 250. The
at least one foam layer 260 may comprise EVA foam, Ariaprene or an
impact mitigation structure. The at least one foam layer 250 being
affixed to the at least one first 240 and at least one second
material 260, and/or disposed between the at least one first
material 240 and the at least one second material 260. The at least
one first 240 or at least one second material 260 may be a two- or
four-way stretch fabric, and/or a sweat wicking or anti-microbial
fabric, where the top or first material and/or bottom or second
material covering may be the same material or the at least one top
and bottom covering may be different materials. For example, the
boot layer first material 240 or second material 260 comprises at
least one of a skin contact fabric material (which could comprise a
wicking material, an anti-microbial material such as Neoprene,
Ducksan Power Net, Diamond pattern), an Ethylene-Vinyl Acetate
(EVA) foam layer or an Ariaprene foam layer, a 4-way stretch
material, and/or any combination thereof, each and/or all of which
could be bonded together using heat pressing techniques, vibration
welding techniques or similar construction techniques, known to
those of skill in the art.
[0085] Accordingly, the boot layer or liner 230 may form a seam
270, the seam 270 may be formed through a heat press, ultrasonic
welding or vibration welding techniques to surround the perimeter
of the boot liner 230. The foam layer can include polymeric foams,
quantum foam, polyethylene foam, polyurethane foam (PU foam
rubber), XPS foam, polystyrene, phenolic, memory foam (traditional,
open cell, or gel), impact absorbing foam, compression foam, latex
rubber foam, convoluted foam ("egg create foam"), EVA foam, VN 600
foam, Evlon foam, Ariaprene or Ariaprene-like material, impact
hardening foam, and/or any combination thereof. The at least one
foam layer may have an open-cell structure or closed-cell
structure. The foam layer can be further tailored to obtain
specific characteristics, such as anti-static, breathable,
conductive, hydrophilic, high-tensile, high-tear, controlled
elongation, and/or any combination thereof.
[0086] As best seen in FIGS. 8A through 8C, various configurations
of boot components can be constructed in simple and/or complex
shapes, including a "butterfly" shape 8A, which allows helmet
components to be manufactured in a "flat" configuration, and then
ultimately be flexed and/or "deformed" into a desired helmet shape
that can easily take the complex contoured shape of the head and/or
that can be combined with other shaped/sized components. In
addition, the various components described herein could be
amendable to additive or "3-D" manufacturing and/or printing
techniques.
[0087] FIG. 9A through 9E depict one exemplary manufacturing
technique for forming a boot layer or liner 290. The boot layer or
liner 290 may comprise a first material 300, a second material 310
and a foam layer 280. In this embodiment, an initial step is to
laser cut a desired shape of the foam layer 280. More specifically,
the foam layer 280 may comprise of EVA foam or Ariaprene. The foam
layer is then laminated with a first material 300 and a second
material 310. The first 300 or second 310 material may have a size
and shape that is larger than the foam layer 280. The first 300 or
second 310 material may comprise a 4-way stretch material (e.g.,
Ducksan DS4015-B45 Power Net) and/or the second material 310 may
comprise a 4-way stretch material (e.g., Diamond Pattern). The
resulting bonded construct can then be die or laser cut to a
desired shape, and subsequently utilized to construct the boot.
Alternatively, FIG. 17 shows another embodiment for forming a boot
layer. FIG. 9C illustrate how the first 300 and second 310
materials are cut into the desired shape of the foam layer 280. The
boot layer or liner 290 may be positioned over an edge compress
tool 320, ensuring the liner edges are aligned with the edge
compress tool 320 edges. The edge compress tool 320 having a recess
330 that conforms to the desired shape of the foam layer 280. A die
cut liner 340 is positioned over the boot layer or liner 290 and
inserted into the recess 330 firmly to "cut" the desired shape.
Accordingly, FIG. 9E illustrates the finished boot layer or liner
350 with the compressed and cut edges.
[0088] FIGS. 10A-10C depicts two exploded cross-sectional views of
an exemplary embodiments of multi-layer construction of a soft
helmet. FIG. 10A depicts a soft-shell helmet 360 that comprises at
least one impact mitigation structure 370 may be affixed to the
boot layer or liner 390. The at least one impact mitigation
structure 370 may comprise a flange 380 that can be welded, glued
or stitched 430 to the boot layer or liner 390. The boot layer or
liner 390 may comprise a first material 400, a second material 420
and a foam layer 410, where the foam layer 410 is disposed between
the first material 420 and a second material 520. Alternatively,
the soft-shell helmet 440 may comprise, wherein an impact absorbing
structural component 370 can be attached to the head boot and/or
encapsulated within a boot "pouch." FIG. 10C depicts a soft-shell
helmet 440 that comprises at least one impact mitigation pad 450,
the at least one impact mitigation pad 450 comprises a first
material 460, a second material 480, and/or an impact mitigation
structure 370. The at least one impact mitigation pad 450 may
further comprise a third material 470. The second material 480 may
extend beyond the width of the impact mitigation structure 370 to
form a flange, and the first material 460 may encapsulate the
impact mitigation structure 370 to form a pouch. A glue strip 490
may be placed under a portion of the second material 480 flange,
such that the glue strip 490 may surround the perimeter of the
impact mitigation structure 370. A plurality of impact mitigation
pads 450 may be affixed to the boot layer 390. The boot layer or
liner 390 may comprise a first material 400, a second material 420
and a foam layer 410, where the foam layer 410 is disposed between
the first material 420 and a second material 520. The first
material 460, the second material 470, and/or the third material
480 may comprise of the same fabrics or different fabrics. The
fabrics may comprise a 2-way stretch material, a 4-way stretch
material, and/or a foam layer (e.g., a stretch knit, a stretch air
mesh, and/or an open cell foam). The foam layer can include
polymeric foams, quantum foam, polyethylene foam, polyurethane foam
(PU foam rubber), XPS foam, polystyrene, phenolic, memory foam
(traditional, open cell, or gel), impact absorbing foam,
compression foam, latex rubber foam, convoluted foam ("egg create
foam"), EVA foam, VN 600 foam, Evlon foam, Ariaprene or
Ariaprene-like material, impact hardening foam, and/or any
combination thereof. The at least one foam layer may have an
open-cell structure or closed-cell structure. The foam layer can be
further tailored to obtain specific characteristics, such as
anti-static, breathable, conductive, hydrophilic, high-tensile,
high-tear, controlled elongation, and/or any combination
thereof.
[0089] FIGS. 11A through 11G depict one exemplary technique for
forming pockets creating an impact mitigation pad, where the
materials can encapsulate the impact absorbing structural
components. In this embodiment, a thermoplastic polyurethane (TPU)
film 510 is initially placed into a TPU forming tool 500, which
then closes and forms a TPU film or a first material 540 within the
each of the cavities/pockets 530 of the tool 520. Then, a plurality
of impact absorbing structures 550 and associated open cell
polyurethane foam layers 560 (the foam layer can be 1 mm to 5 mm
thick) can be inserted into the pockets that form the first
material 540 (FIG. 11D), and a hotmelt layer 570 with release paper
580 can be applied to the formed TPU 520 (FIG. 11E). Alternatively,
the pockets or the impact mitigation pads can be bonded to the
liner using ultrasonic welding or high-frequency welding (e.g.,
using a controlled vibration of the tooling to partially liquify
the TPU material itself and weld the flanges or base of the pocket
to the liner). The pockets can then be die cut 590 (FIG. 11F) and
removed from the TPU form tool 520. FIG. 11G depicts an isometric
view of the plurality of individual impact mitigation pads 600
after they were die cut 590 into separate pads. FIG. 16 depicts an
alternative method for forming pockets that encapsulate the impact
absorbing structure.
[0090] FIGS. 12A through 12C and FIG. 15 illustrate one exemplary
technique for bonding the impact mitigation pads 600, i.e., the
pockets and impact absorbing structures, to the liner or at least
one boot layer. In this embodiment, the impact mitigation pads 600
or pockets are first inserted into the tool cavity 620, and then
the liner component 620 is inserted into or over the tool 610. Heat
and pressure are applied by the tool 610 in a known manner, and
then the tool 610 is opened and the completed part removed for use
and/or further assembly. Alternatively, the liner and/or the boot
layer 620 can be bonded together using ultrasonic welding or
high-frequency welding (e.g., using a controlled vibration of the
tooling to partially liquify the materials and weld the liner to
the boot layer together). FIG. 12C depicts a front view of one
exemplary embodiment of a completed soft shell helmet 630
comprising one or more impact mitigation pads 600 and a liner
620.
[0091] FIGS. 13A-13C depict one embodiment of a soft shell helmet
design as similarly shown in FIGS. 2A and 3A. FIGS. 13A-13B show a
side and a front view of the soft-shell helmet of FIGS. 2A-3A. The
soft shell helmet comprises a liner 50 and at least one impact
mitigation structure 60 affixed to the liner 50. The soft shell
helmet may further comprise an ear aperture 70, the ear aperture 70
may be sized and configured to fit a wearer's ear shape. FIG. 13C
illustrates a covered soft-shell helmet 45, the covered soft-shell
helmet 45 comprises a cover 55, a liner 50, and at least one impact
mitigation structure 60 affixed to the liner 50. The cover 55 would
encapsulate the entire liner 50 and at least one impact mitigation
structure 60 assembly to provide protection from sweat and/or
anti-microbial protection.
[0092] FIGS. 14 and 15A-15C illustrates one exemplary embodiment
for forming a soft shell helmet 640. The soft shell helmet 640 may
comprise a plurality of liner assemblies, where each of the
plurality of liner assemblies 650 comprise a liner 660 and at least
one impact mitigation pad 650. Each of the plurality of liner
assemblies 650 or segments are connected to an adjacent liner
segments or liner assemblies 650. The liner assemblies 650 or
segments or a plurality of boot layers can be connected to each
other using various methods known in the art. Such connections may
include ultrasonic welding, RF welding, stitching, gluing, stretch
seam taping, Velcro, riveting, and/or any combination thereof. More
specifically, each of the liner assemblies 650 may have the liner
660 that extended edge a certain width beyond the at least one
impact mitigation pad 650, which the liner edge 680 extends allows
the edges 680 to be coupled to each other to form a soft-shell
helmet 640. The liner segments or a plurality of boot layers may
provide for a border or periphery that surrounds each liner segment
to provide additional features. Such additional features may
include a snap button pose for a chinstrap mount (not shown),
through-holes 670, and/or a seam edge to affix the adjacent edge to
each other.
[0093] In various embodiments, the impact mitigation structures can
incorporate varying offsets (i.e., array thickness as measured in a
perpendicular direction outward from the surface of the wearer's
head), including offsets of 4 to 6 millimeters, 7 to 9 millimeters
and/or 11 to 13 millimeters. The soft helmets can be provided in a
variety of sizes (3 sizes, in at least one example), with each size
desirably accommodating a range of head sizes, with overlap between
each member of each range.
[0094] In various embodiments, the overall thickness of the soft
helmet could be 8 millimeters or less, which is a significant
improvement over competitive designs that can be 15 to 20
millimeters or more in thickness.
[0095] FIGS. 16A-16B depict an alternative embodiment to
manufacture at least one impact mitigation pad 690. FIG. 16A
depicts an impact mitigation pad 690 that comprises a first
material 700, a second material 740, and/or an impact mitigation
structure 710. The at least one impact mitigation pad 690 may
further comprise a third material 720. The second material 740 may
extend beyond the width of the impact mitigation structure 710 to
form a flange, and the first material 700 may encapsulate the
impact mitigation structure 700 to form a pouch. The first material
700 contacts the second material 740 in order to create a seam 730,
the seam 730 may be created with ultrasonic welding, RF welding,
stitching, gluing, stretch seam taping, Velcro, riveting, and/or
any combination thereof. The first material 460, the second
material 470, and/or the third material 480 may comprise of the
same fabrics or different fabrics. The fabrics may comprise a 2-way
stretch material, a 4-way stretch material, and/or a foam layer
(e.g., a stretch knit, a stretch air mesh, stretch poly, and/or an
open cell foam). FIG. 16B illustrates various embodiments of impact
mitigation pads.
FIGS. 17A-17C depict different views of another embodiment of a
liner 750. The liner 750 may comprise a first material 760, a
second material 780, and a foam layer 770, the foam layer 770
disposed between the first material 760 and the second material
780. The first material 760, the second material 780, and/or the
foam layer 770 may comprise of the same fabrics/materials or
different fabrics/materials. The fabric/materials may comprise a
2-way stretch, a 4-way stretch, a foam material (e.g., EVA or
Ariaprene). The liner 750 may have sealed seam 790 that surrounds
the perimeter of the liner 750. The sealed seam may be
approximately 1 mm to 5 mm. The foam layer can include polymeric
foams, quantum foam, polyethylene foam, polyurethane foam (PU foam
rubber), XPS foam, polystyrene, phenolic, memory foam (traditional,
open cell, or gel), impact absorbing foam, compression foam, latex
rubber foam, convoluted foam ("egg create foam"), EVA foam, VN 600
foam, Evlon foam, Ariaprene or Ariaprene-like material, impact
hardening foam, and/or any combination thereof. The at least one
foam layer may have an open-cell structure or closed-cell
structure. The foam layer can be further tailored to obtain
specific characteristics, such as anti-static, breathable,
conductive, hydrophilic, high-tensile, high-tear, controlled
elongation, and/or any combination thereof.
[0096] FIG. 20-21 depict another embodiment of an undulating impact
mitigation structure 810. The undulating impact structure 810
having a plurality of undulating walls 820 forming an array, each
of the undulating walls 820 having a cross-sectional shape 830, the
cross-sectional shape 830 having a first portion 840 and a second
portion 850, the second portion 840 comprises a longitudinal member
that extends perpendicular from the first portion 840. The second
portion 850 having a length 860 and a width 870 to form an aspect
ratio. If the length is greater than the width, a high aspect ratio
structure, the second portion 850 can be more prone to buckling,
the buckling being a sudden lateral deflection away from the
longitudinal axis of the undulating walls 820. The aspect ratio may
be between 3:1 to 1,000:1, where the length is greater than the
width. The cross-sectional shape may comprise a solid or hollow
shape. The longitudinal member may comprise a conical or frustum
shaped structure, but it also may comprise a square, cylinder,
triangle, shaped structure. The undulated walls 820 may comprise
herringbone shape 880, chevron shape 890, a zig zag shape 900,
and/or any combination thereof as shown in FIG. 21. FIGS. 22A-22E
depict an alternative embodiment of a full-coverage soft shell
helmet. The full coverage soft shell helmet may comprise at least
one of a boot layer or liner, one or more individual impact pads or
individual impact pad assemblies, a chinstrap, ear protection
elements and/or any combination thereof. The soft shell helmet 910
comprising a liner 920, one or more impact mitigation pads 930. The
one or more impact mitigation pads 930 are affixed to the liner
920. The liner 920 may comprise apertures 940 that allow
ventilation. The at least one "boot layer," or "liner" 920 may
comprise at least one material layer or a plurality of material
layers. The at least one boot layer 920 may comprise a single
material layer. Alternatively, the at least one boot layer 920 may
comprise a first material and a second material. The at least one
boot layer 920 may be custom manufactured to fit the desired head
of the player and/or be manufactured to standard sizes (small,
medium, large, x-large, etc.) The at least one boot layer 920 may
be manufactured to accommodate and protect the desired region of
the player's head. The desired regions may include the front, upper
sides (right and left) lower sides (right and left), ridge (top of
head), mid back, lower back, jaw, temples, and/or any combination
thereof. In a preferred embodiment, the at least one boot layer 920
may comprise a first material, a second material, and a foam layer
and/or any combination thereof.
[0097] The one or more individual impact pads or individual impact
pad assemblies may permanently and/or removably affixed or coupled
to the at least one boot layer or liner and regionally placed
around the player's head for enhanced protection. The one or more
individual impact pads and/or impact pad assemblies may be
desirably positioned on different regions of the head, including
the frontal section, top or ridge section, lower back, mid-back,
left side and front side, temples, jaw region and/or any
combination thereof. For example, FIGS. 23A-23B and 24 depict one
embodiment of a front impact pad assemblies 950, 980 and/or a rear
impact pad assemblies 970, which each of the front 950 and rear 970
assemblies comprise one or more impact mitigation pads 960.
[0098] FIGS. 25A-25B and 26A-26B depict another exemplary
alternative embodiment of an individual impact mitigation pad 990.
The at least one or more individual impact mitigation pads 980 may
comprise at least one impact structure 1040 at least one first
layer or material 1000. The first layer or material 1000 comprises
a flange 1010, the flange 1010 surrounds a perimeter of one end of
the first layer or material 1000 and at least one recess 1020
forming a pocket, the pocket having a pocket height 1050, and the
pocket may be shaped and configured to receive the impact
mitigation structure 1040. The first layer or material 1000 may
further comprise ventilation holes 1030 the pocket having a pocket
height 1050 the impact mitigation structure 1040 disposed within
the pocket. The impact mitigation structure may comprise a portion
of filaments, laterally supported filaments, auxetic structures,
and/or undulating structures. In one embodiment, the impact
mitigation structure 1040 can comprise undulating structures. The
undulating structures comprise a plurality of spaced apart elongate
walls, each of the plurality of elongate walls having a height and
an undulated pattern, each of the plurality of elongate walls
having a cross-sectional shape including a first lower portion and
a second upper portion, the first lower portion comprising a base
having a cross-sectional width and a height, the second upper
portion comprising an upwardly extending longitudinal member, the
upwardly extending longitudinal member extending generally
perpendicular from the base and having a cross-sectional width and
a height, the base width is greater than the upwardly extending
longitudinal member width and the base height is less than the
upwardly extending longitudinal member height; and at least one
support member, the at least one support member extending at least
a portion of a length of the plurality of spaced apart elongate
walls Furthermore, the plurality of spaced apart elongate walls is
disposed within the pocket, where the plurality of spaced apart
walls having an end that is flush with the perimeter of the pocket.
Alternatively, the plurality of spaced part walls having an end
that extends beyond the perimeter of the pocket or below the
perimeter of the pocket. The height and undulated pattern may be
uniform or non-uniform. Furthermore, each of the individual impact
mitigation pads 990 may comprise a one-piece assembly that
integrates the impact mitigation structure within the at least one
first layer. The one-piece impact mitigation structure may be
injection molded, 3D printed, casted, thermoformed and/or die cut
with the first layer as a one-piece construct.
[0099] FIGS. 27A-27B depicts the impact mitigation pad assembly
1060. The impact mitigation pad assembly 1060 comprises an impact
mitigation pad 990, at least one first layer 1070 and at least one
second layer 1080. Alternatively, the impact structure assembly may
further comprise a top and/or a bottom covering. The at least one
first layer 1070 or the at least one second layer 1080 may be
coupled and/or affixed to the impact mitigation pad 990, the impact
mitigation structure (not shown) and/or impact structure assembly.
The at least one first layer or the at least one second layer may
include a 2-way stretch material, a four-way stretch material, at
least one foam layer, at least one polycarbonate layer or a force
distribution layer, a hotmelt layer, boot layer and/or any
combination thereof. The at least one first and/or at least one
second covering may be a two- or four-way stretch fabric (e.g.
Lycra), where the top and bottom covering may be the same material
or the at least one top and bottom covering may be different
materials. The at least one top covering and/or at least one bottom
covering may be coupled to the impact mitigation structure and/or
the impact mitigation structure assembly as shown by FIGS. 28A-28B.
The coupling may include stitching, hook and loop fasteners, snaps,
adhesive, melting, any form of welding known in the art. The
polycarbonate layer can be thin, flexible, yet substantially rigid
to assist with absorption of the forces and reduce wear/tear. The
foam layer can include polymeric foams, quantum foam, polyethylene
foam, polyurethane foam (PU foam rubber), XPS foam, polystyrene,
phenolic, memory foam (traditional, open cell, or gel), impact
absorbing foam, latex rubber foam, convoluted foam ("egg create
foam"), EVA foam, VN600 foam, Evlon foam, Ariaprene or
Ariaprene-like material, impact hardening foam, compression foam,
and/or any combination thereof. The at least one foam layer may
have an open-cell structure or closed-cell structure. The foam
layer can be further tailored to obtain specific characteristics,
such as anti-static, breathable, conductive, hydrophilic,
high-tensile, high-tear, controlled elongation, and/or any
combination thereof. Each of the impact pad assemblies 1060 may be
affixed to a liner 1090. The affixation may comprise ultrasonic
welding, gluing, hot melt, etc. The one or more individual impact
pads and/or impact pad assemblies 1060 may be desirably positioned
on different regions of the head, including the frontal section,
top or ridge section, lower back, mid-back, left side and front
side, temples, jaw region and/or any combination thereof.
[0100] FIGS. 29A-29F and/or 30A-30C depict one embodiment of the
manufacture of a full-coverage soft shell helmet. In one
embodiment, creating a plurality of individual impact pads and/or
individual impact pad assemblies, coupling the plurality of
individual impact pads to a least one boot layer, cutting the boot
layer to substantially match the perimeter of the plurality of
individual impact pads leaving a 0 to 6 mm edging, coupling a
portion of the booth layer edging to the proximate base layer
edging to form a circumferential shaped construction. Such process
may be repeated for the front pad assembly and the rear pad
assembly, then coupled to each other to form the circumferential
shaped construction as shown in FIGS. 31A and 31B. In one
embodiment, the soft shell helmet 1180 comprises a front pad
assembly 1100 and a back panel pad assembly 1150 and a base layer
1120. Each of the front panel assembly 1100 and/or the back panel
pad assembly 1150 comprises a plurality of impact mitigation pads
990 or impact mitigation pad assemblies 1060. The method to
manufacture a soft shell helmet comprises the steps of die cutting
the plurality of foam panels 1110 that substantially conforms or
conforms to the shape and configuration of the plurality of impact
mitigation pads 990 and/or the plurality of impact mitigation pad
assemblies 1060, bonding the foam panels 1110 to a base layer 1120
(e.g., a 2-way or 4-way stretch material), cutting the base layer
1129 with the plurality of foam panels 1110 to create a custom base
layer 1120 that substantially conforms to the plurality of impact
mitigation pads 990 and/or plurality the impact mitigation pad
assemblies 1060, replacing at least a portion of the foam panels
1110 with a portion of the plurality of impact mitigation pads 990
and/or the impact mitigation pad assemblies 1060 and affixing them
to the base layer, flexing the tabs 1140 of the base layer to
conform to the head of a wearer, affixing the remaining the impact
mitigation pads 990 and/or the impact mitigation pad assemblies
1060 to the base layer.
[0101] Accordingly, the front pad assembly 1100 with the back pad
assembly 1150 must be affixed or coupled together to create the
soft shell helmet 1180 as shown in FIGS. 31A-31C. The key impact
mitigation pad 1160 has a first end and a second end. The first end
is affixed to the front pad assembly 1100 and the second end is
affixed to the back pad assembly 1150 creating a seam or stitch
1170. The back pad assembly 1150 is flexed to conform to the head
of the wearer. The back pad assembly having tabs 1140 that may
couple a chin strap (not shown).
[0102] FIGS. 38A-38G depict different plan views of an alternate
embodiment of a soft-shell helmet 1380. The soft-shell helmet 1380
may comprise a plurality of impact pads 1390 and a liner 1400. The
liner may comprise one or more material layers. The one or more
material layers may comprise a 2-way stretch material, a 4-way
stretch material, a foam layer, and/or any combination thereof. The
liner may further comprise an impact mitigation structure (not
shown) and one or more ventilation holes 1430, 1420.
[0103] The plurality of impact mitigation pads 1390 may comprise an
impact pad assembly. The impact pad assembly comprises an impact
mitigation pad 990, a first material layer 1070, a second material
layer 1080 as shown in FIGS. 27A-27B. The impact mitigation pad 990
comprises a base material layer (or first material layer), the
first material layer or base material layer having a first surface
and a second surface, a recess disposed onto a first surface
extending towards the second surface, the recess having a recess
height; and an impact mitigation structure, the impact mitigation
structure comprising a plurality of spaced apart elongated walls,
the plurality of spaced apart walls disposed within the recess,
each of the plurality of elongated walls having a height, a width
and a undulated pattern, each of the plurality of elongated walls
having a cross-sectional shape.
[0104] Alternatively, the plurality of impact pads 1390 may
comprise a first material layer or base material layer having a
first surface and a second surface, a recess disposed onto a first
surface extending towards the second surface, the recess having a
recess height; and an impact mitigation structure, the impact
mitigation structure comprising a plurality of spaced apart
elongated walls, the plurality of spaced apart walls disposed
within the recess, the recess having a recess height, each of the
plurality of elongated walls having a height, a width and a
undulated pattern, each of the plurality of elongated walls having
a cross-sectional shape.
[0105] Each of the plurality of elongated walls or a plurality of
elongated walls may comprise a uniform height, width and undulated
pattern. Alternatively, each of the plurality of elongated walls or
a plurality of elongated walls may comprise a non-uniform height,
width and undulated pattern. The elongated wall height may comprise
a range between 6 mm to 1.2 cm. The undulated pattern may be may
comprise herringbone shape 880, chevron shape 890, a zig zag shape
900, and/or any combination thereof as shown in FIG. 21.
Furthermore, in another embodiment, the plurality of impact pads
1390 may comprise only a first material layer or base material
layer. Furthermore, each of the plurality of elongated wall height
is less than, equal to, and/or greater than the recess height.
Also, a plurality of impact pads 1390 may further comprise
ventilation holes.
[0106] In addition, the elongated wall height may be a high-aspect
ratio structure. If the length is greater than the width, a high
aspect ratio structure, the impact mitigation structure 1370 can be
more prone to buckling, the buckling being a sudden lateral
deflection away from the longitudinal axis of the elongated walls.
The aspect ratio may be between 3:1 to 1,000:1, where the length is
greater than the width. The cross-sectional shape may comprise a
solid or hollow shape. The longitudinal member may comprise a
conical or frustum shaped structure, but it also may comprise a
square, cylinder, triangle, shaped structure. The elongated walls
may also undergo elastic deformation, allowing the elongated walls
to return to its initial configuration after an impact. The first
or base material layer 1070 and/or the second material layer 1080
may comprise a 2-way stretch material, a 4-way stretch material, a
polymer or polycarbonate material, and/or a foam layer. The foam
layer can include polymeric foams, quantum foam, polyethylene foam,
polyurethane foam (PU foam rubber), XPS foam, polystyrene,
phenolic, memory foam (traditional, open cell, or gel), impact
absorbing foam, latex rubber foam, convoluted foam ("egg create
foam"), EVA foam, VN600 foam, Evlon foam, Ariaprene or
Ariaprene-like material, impact hardening foam, compression foam,
and/or any combination thereof. The at least one foam layer may
have an open-cell structure or closed-cell structure. The foam
layer can be further tailored to obtain specific characteristics,
such as anti-static, breathable, conductive, hydrophilic,
high-tensile, high-tear, controlled elongation, and/or any
combination thereof.
Ventilation/Cleaning Features
[0107] In various embodiments, the outer surface of the soft helmet
can externally expose the various voids within the impact absorbing
structures, which could significantly improve ventilation, wicking
and/or cooling of the helmet and the player beneath (see FIGS. 13B
and 13C), as well as allow free expression of fluids in water
sports such as diving and/or water polo. Alternatively, an outer
layer of material could be provided which isolates and/or protects
the voids, which could desirably prevent mud, grass or other soils
from contaminating and/or filling the voids, if desired (see FIG.
13A). If desired, the outer material layer could comprise an over
layer of mesh or foam over the top of the helmet. In various
embodiments, the soft helmet would incorporate machine washable
and/or dryable materials and/or construction.
[0108] In various alternative embodiments, some portion of the
impact mitigation structures may have an outer covering, including
outer coverings in some regions of the soft helmet and with no
outer coverings in other regions of the soft helmet.
Head Cap Top
[0109] In various embodiments, a soft helmet could include a ridge,
dome or peak section that covers the top of the wearer's head. This
could include one or more impact absorbing structures and related
components to protect the top of the wearer's head. The peak
section could cover the entire top of the wearer's head, or some
portions thereof, depending upon user desire and comfort. The dome
or peak section may be removably coupled or permanently integrated.
The dome or peak section may be removably coupled using methods
known in the art, such as stitching, Velcro (hook & loop),
snaps, magnets, and/or any combination thereof.
Headband/Sweat Band
[0110] In at least one exemplary embodiment, a soft helmet could
comprise a head band or sweat band structure 800, 1190, 1200 for
encircling at least a portion of the wearer's head, with the band
incorporating at least one impact mitigating structure therein
and/or thereupon (see FIG. 18 and FIGS. 32A-32B, 33A-33B, and
34B-34C). In such an embodiment, the band could include a uniform
and/or smooth outer surface, which might provide a more desirable
exterior surface and/or surface profile for use in sports such as
soccer, where impacts with the players head/head band and the
soccer ball would not significantly degrade ball rebound and play.
The headband 800, 1190, 1200 may comprise hidden stitches that
surround the top surface and the bottom surface of the headband. In
one exemplary embodiment, the headband 1200 may comprise a first
portion 1270 and a second portion 1260. Each of the first portion
1270 and the second portions 1260 comprise a first material 1220
and a second material 1230, and an impact mitigation structure
1250, the impact mitigation structure 1250 disposed between the
first material 1220 and the second material 1230. The first portion
1270 may be sized and configured to conform to the lower back to
mid back region of the wearer's head, and the second portion 1260
may be sized and configured to conform to the forehead of the
wearer's head. The first portion 1270 and the second portion may be
affixed by an intermediary material 1280. Such intermediary
material 1280 may be a 2-way stretch material, a 4-way stretch
material, or a foam layer, where an internal stitch or seam 1240 is
created to affix the first 1270 and second 1260 portions together.
FIGS. 33C and 33D show a side view and a front view of one
embodiment of a headband 1200. These views represent the total area
in which graphic printing may be available and can be directly
disposed onto the first material 1220.
[0111] The headband 800, 1190, 1200 may have different standard
sizes. Such standard sizes may include, small, medium, large,
xlarge, etc. The sizes can have a width or circumference of 40 to
70 cm. The first material 1220 and the second material 1230 may
comprise TLC AP, with a 65 C shore hardness, a 2-way stretch,
and/or a 4-way stretch. The impact mitigation structure 1250 can be
a portion of filaments, a portion of laterally supported filaments,
auxetic structures, undulating structures, and/or any combination
thereof. The headband may comprise a rear seam 1300 and/or a side
internal stitch or seam 1240.
[0112] In at least one exemplary embodiment, a "soft" shell helmet
can include a protective headband. The protective headband may
comprise a tubular or generally cylindrical shape and
configuration, which desirably fits around the circumference of an
upper portion of the wearer's head (i.e., across the forehead and
above a portion of the ears and potentially covering the mid-back
region). The soft-shell helmet headband may comprise at least one
first layer, at least one second layer, and/or at least one impact
mitigation structure or impact mitigation structure assembly as
shown in FIGS. 33A-33C and 34. Alternatively, the soft-shell helmet
headband may comprise at least one first layer, at least one second
layer, at least one impact mitigation structure or impact
mitigation structure assembly, a top covering and/or any
combination thereof as shown in FIGS. 36A-36B.
[0113] The at least one first layer or the at least one second
layer may be one or more of the following: a foam layer,
polycarbonate layer, two- or four-way stretch fabric (e.g. Lycra),
a hotmelt layer, boot layer and/or any combination thereof. The at
least one first layer or at least one second layer may be the same
material or may be different materials. The polycarbonate layer can
be thin, flexible, yet substantially rigid to assist with
absorption of the forces and reduce wear/tear. The foam layer can
include polymeric foams, quantum foam, polyethylene foam,
polyurethane foam (PU foam rubber), XPS foam, polystyrene,
phenolic, memory foam (traditional, open cell, or gel), impact
absorbing foam, latex rubber foam, convoluted foam ("egg create
foam"), EVA foam, VN600 foam, Evlon foam, Ariaprene or
Ariaprene-like material, impact hardening foam, and/or any
combination thereof. The at least one foam layer may have an
open-cell structure or closed-cell structure. The foam layer can be
further tailored to obtain specific characteristics, such as
anti-static, breathable, conductive, hydrophilic, high-tensile,
high-tear, controlled elongation, and/or any combination thereof,
and may be 0.5 mm to 3 mm thick, and 45-60 cm in diameter. The at
least one top covering may be a two- or four-way stretch fabric
that may be standard sized and/or a custom sized. The custom sized
style fabric (see FIG. 36A) that may be added or removed from
soft-shell headband to be washed as shown in FIG. 36B. Such custom
style enclosure can be cut to substantially match the soft-shell
helmet headband shape and configuration.
[0114] FIGS. 35A-35B depict one embodiment of an impact mitigation
structure 1250 for assembly into a soft-shell helmet headband. The
method comprises cutting the impact structure and/or impact
structure assembly to custom shape with tabs 1310 that extends from
the impact mitigation structure 1250, flexing the tabs 1310 until
they connect with a portion of the impact mitigation structure
1250, the connection may comprise gluing, stitching, welding, etc.
The impact mitigation structure 1250 is affixed to a second
material 1230 by creating side internal stitches 1240. Coupling an
intermediary material or layer 1280 over the side internal stitches
1240 and affix into position; the intermediary material or layer
1280 may comprise VN-600 foam layer; coupling the first material
1220 to the impact mitigation structure 1250 with at least one or
more stiches 1290 (the at least one or more stitches 1290 may align
with the side internal stiches of 1240) to create a headband 1300.
Alternatively, coupling the impact structure and/or impact
structure assembly to first or second layer, coupling the first or
second layer to the impact structure, impact structure assembly
and/or the first or second layer; alternatively, a removably
coupling a top covering layer over the soft-shell helmet headband
assembly.
[0115] FIGS. 36A-36B depict an alternative embodiment of a headband
1310. The headband 1310 may comprise a headband skin 1320 that may
be removably coupled to a standard headband 1300. The headband skin
1310 having a width 1330, the width being 20-40 cm wide. The
headband skin 1310 may be a 2-way stretch or 4-way stretch material
with different patterns, colors and/or logos so the wearer may have
the flexibility of choosing a headband skin 1310 to fit the
wearer's personality.
[0116] FIGS. 37A-37D depict different views and one exploded view
of an alternate embodiment of a headband 1340. The headband 1340
may comprise a first portion 1355 and a second portion 1345, each
of the first 1355 and the second 1345 portion comprises at least a
first material 1350 a second material 1360, and an impact
mitigation structure 1370. The impact mitigation structure 1370 may
comprise a portion of filaments, a portion of laterally supported
filaments, a portion of undulated structures, and/or any
combination thereof. The first portion 1355 and the second portion
1345 are coupled together to form a shape that conforms around the
circumference of wearer's head. The coupling may comprise
stitching, gluing, welding, Velcro, and/or any other mechanical
connection. In one exemplary embodiment, the impact mitigation
structure 1370 is an undulated structure. The undulated structure
comprises a plurality of spaced apart elongated walls, each of the
plurality of elongated walls having a wall height and a undulated
pattern, each of the plurality of elongated walls having a
cross-sectional shape, the cross-sectional shape including a first
lower portion and a second upper portion, the first lower portion
comprising a base having a cross-sectional base width and a base
height, the second upper portion comprising an upwardly extending
longitudinal member, the upwardly extending longitudinal member
extending generally perpendicular from the base and having a
cross-sectional longitudinal member width and a longitudinal member
height, the base width is greater than the longitudinal width and
the base height is less than the longitudinal member height; and at
least one support member, the at least one support member
perpendicularly extending at least a portion of a length of the
plurality of spaced apart elongated walls. The impact mitigation
structure 1370 may further comprise a border, the border surrounds
the perimeter of the impact mitigation structure 1370, the border
having a border height, the border height substantially equivalent
or equivalent to the wall height. The wall height may be a range
between 6 mm to 1.2 cm. Increasing the base width will provide more
surface area for contacting the wearer's head and facilitates the
distribution of forces.
[0117] In addition, the wall height and/or the longitudinal member
height may be a high-aspect ratio structure. If the length is
greater than the width, a high aspect ratio structure, the impact
mitigation structure 1370 can be more prone to buckling, the
buckling being a sudden lateral deflection away from the
longitudinal axis of the elongated walls. The aspect ratio may be
between 3:1 to 1,000:1, where the length is greater than the width.
The cross-sectional shape may comprise a solid or hollow shape. The
longitudinal member may comprise a conical or frustum shaped
structure, but it also may comprise a square, cylinder, triangle,
shaped structure. The elongated walls may comprise herringbone
shape 880, chevron shape 890, a zig zag shape 900, and/or any
combination thereof as shown in FIG. 21. The elongated walls may
also undergo elastic deformation, allowing the elongated walls to
return to its initial configuration after an impact.
[0118] Furthermore, the at least a first material 1350 and a second
material 1360 may comprise a foam layer or foam material, a 2-way
stretch material and/or a 4-way stretch material. The at least a
first material 1350 and a second material 1360 may comprise
different materials or the same materials. In addition, the at
least a first material 1350 and a second material 1360 may further
comprise a coating or laminate that is disposed on an interior
surface or an exterior surface of the at least a first material
1350 and a second material 1360. Such coating or laminate may
comprise a flexible fabric or a urethane. The at least a first
material 1350 and a second material 1360 may further comprise one
or more ventilation holes 1365, where the one or more ventilation
holes 1365 may extend from the first material 1350 through the
second material 1360, and/or the one or more ventilation holes 1365
may extend a portion from the first material 1350 towards the
second material 1350. The foam layer can include polymeric foams,
quantum foam, polyethylene foam, polyurethane foam (PU foam
rubber), XPS foam, polystyrene, phenolic, memory foam (traditional,
open cell, or gel), impact absorbing foam, latex rubber foam,
convoluted foam ("egg create foam"), EVA foam, VN600 foam, Evlon
foam, Ariaprene or Ariaprene-like material, impact hardening foam,
compression foam, and/or any combination thereof. The at least one
foam layer may have an open-cell structure or closed-cell
structure. The foam layer can be further tailored to obtain
specific characteristics, such as anti-static, breathable,
conductive, hydrophilic, high-tensile, high-tear, controlled
elongation, and/or any combination thereof.
Ear Protection/Shell Elements
[0119] In various embodiments, the soft helmet could incorporate
auxiliary protection features, such as ear caps or other relative
more rigid structures, which could comprise modular components for
addition to the helmet if desired. As best seen in FIGS. 19A and
19B, and ear cap could comprise a molded thermoplastic cup or shell
or a foam material, which desirably fits within an ear opening of
the soft helmet. The foam material may be compression molded foam
to provide a softer and/or more compliant construction. The foam
material may be comprised of memory foam, open or closed cell foam,
impact foam, ethylene-vinyl acetate (EVA), thermoplastic elastomer
(TPE) or a EVA-TPE hybrid, and/or any combination thereof. The cup
can include one or more openings to facilitate sound transmission,
if desired. Desirably, the ear cap will include a central raised
region for accommodating the ear and ear lobes of the wearer, which
can extend through an ear opening of the helmet, with a peripheral
flange or other feature which can be retained by the helmet (which
stretches around the ear cap in a desired manner to accommodate ear
caps of varying sizes).
[0120] In another exemplary embodiment, the soft-shell helmet may
comprise a chin-strap buckle. The chin-strap may be integrated with
the boot layer and/or as a separate, independent feature that may
be removably coupled. If the separate, independent chin-strap is
removably coupled, the soft-shell helmet may include a through hole
where a chin strap may be affixed and a buckle to allow
adjustability. Alternatively, if the chin-strap is integrated with
the boot layer, the chin-strap would be designed with elasticity to
allow the player's chin to stretch the chin-strap to accommodate
the different "chin" size and configurations. Such chin-straps can
help support and/or retain the soft-shell helmet on the head of the
wearer. The chin-strip may be manufactured using an elastic
material and may include impact mitigation pads or other impact
mitigation structures affixed to the chin-strap, if desired.
Eye Protection
[0121] In another embodiment, the soft helmet may comprise a visor,
eyewear and/or eye shields. The visor may be removably
connected/coupled or integrated within the soft helmet. Such
removable connections may include magnets, buckles, elastic bands,
Velcro, snaps, quick release mechanism, friction, and/or any
combination thereof. The visor may be manufactured with a polymer
that has specific material characteristics to enhance or protect
optical viewing. For example, such characteristics may include a
shatterproof material, an anti-fog coating, anti-glare coating,
anti-scratch coating, an anti-reflective coating, photochromic
coating, tinting, UV coating, prescription based, and/or any
combination thereof. The visor may be substantially flexible and
curved to allow insertion under the soft helmet. The soft helmet
may have a specific visor opening, where the visor may be
positioned. The visor having a flange surrounding the perimeter may
be disposed within the visor opening, the soft helmet inner surface
may hold the flange of the visor in place. Alternatively, the visor
may have mechanical connections that allow the visor to be
removably connected to the external surface of the soft helmet.
Supplemental Protection Cap
[0122] If desired, a soft helmet could also provide an enhanced
"underlayer" of protection within an existing protective helmet,
such as within a hard, rigid or substantially rigid shell helmet.
In essence, the soft helmet could be worn as a "skull cap" within
the shell helmet, and provide additional impact protection
thereto.
Configurable Helmet
[0123] In at least one alternative embodiment, a soft helmet may
comprise a cylindrical/round cap or latticed framework or similar
arrangement, that could allow for various designs and/or
configurations of impact absorbing structures to be added and/or
removed from the helmet structure, depending upon player
preference. For example, the latticed framework may comprise a hook
and loop fastener surface, that attaches to corresponding surfaces
on the impact absorbing structures. This could include the
placement of impact mitigations structures in desired
locations/arrangements to accommodate sport specific and/or
position specific impact needs, including the use of impact
protective elements that are modular and/or segmented structures
that can be affixed to the exterior and/or interior of the soft
helmet to achieve a desired helmet.
[0124] The entire disclosure of each of the publications, patent
documents, and other references referred to herein is incorporated
herein by reference in its entirety for all purposes to the same
extent as if each individual source were individually denoted as
being incorporated by reference.
[0125] The invention may be embodied in other specific forms
without departing from the spirit or essential characteristics
thereof. The foregoing embodiments are therefore to be considered
in all respects illustrative rather than limiting on the invention
described herein. The scope of the invention is thus intended to
include all changes that come within the meaning and range of
equivalency of the descriptions provided herein.
[0126] Many of the aspects and advantages of the present invention
may be more clearly understood and appreciated by reference to the
accompanying drawings. The accompanying drawings are incorporated
herein and form a part of the specification, illustrating
embodiments of the present invention and together with the
description, disclose the principles of the invention.
[0127] Although the foregoing invention has been described in some
detail by way of illustration and example for purposes of clarity
of understanding, it will be readily apparent to those of ordinary
skill in the art in light of the teachings of this invention that
certain changes and modifications may be made thereto without
departing from the spirit or scope of the disclosure herein.
* * * * *