U.S. patent application number 17/184983 was filed with the patent office on 2021-08-26 for full-face helmet system.
The applicant listed for this patent is VPG Acquisition, LLC (d/b/a VICIS), VPG Acquisition, LLC (d/b/a VICIS). Invention is credited to Miguel HERRERA, Jason NEUBAUER.
Application Number | 20210259350 17/184983 |
Document ID | / |
Family ID | 1000005430626 |
Filed Date | 2021-08-26 |
United States Patent
Application |
20210259350 |
Kind Code |
A1 |
NEUBAUER; Jason ; et
al. |
August 26, 2021 |
Full-Face Helmet System
Abstract
The full-face helmet system comprises a full-facemask that
combines the strength of a facemask frame and a reinforcement layer
to allow for improved visibility, safety and impact performance,
while reducing weight. The full-facemask comprises a reinforcement
layer and a facemask frame, the reinforcement layer may be coupled
to the external surface or internal surface of a facemask frame.
The reinforcement layer may match or substantially match one or
more contours of the facemask frame, the reinforcement layer
comprises at least one vent opening that is coincident with the
player's mouth.
Inventors: |
NEUBAUER; Jason; (Seattle,
WA) ; HERRERA; Miguel; (Seattle, WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
VPG Acquisition, LLC (d/b/a VICIS) |
New York |
NY |
US |
|
|
Family ID: |
1000005430626 |
Appl. No.: |
17/184983 |
Filed: |
February 25, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62981701 |
Feb 26, 2020 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A42B 3/225 20130101;
A42B 3/20 20130101; A42B 3/06 20130101 |
International
Class: |
A42B 3/20 20060101
A42B003/20; A42B 3/22 20060101 A42B003/22; A42B 3/06 20060101
A42B003/06 |
Claims
1. The full-face facemask comprising: a facemask frame, the
facemask frame comprising an external surface and an internal
surface, the facemask comprising an upper bar and a lower bar; and
a reinforcement layer, the reinforcement layer coupled to the
external surface of the facemask frame, at least a portion of the
reinforcement layer substantially matches the shape of the facemask
frame, the reinforcement layer comprises at least one vent opening
coincident with a player's mouth.
2. The full-face facemask of claim 1, wherein the reinforcement
layer comprises a clear or transparent plastic material.
3. The full-face facemask of claim 1, wherein the at least one vent
opening comprises a plurality of openings.
4. The full-facemask of claim 3, wherein the reinforcement layer
further comprises a plurality of openings disposed adjacent to the
at least one vent opening.
5. The full-facemask of claim 1, wherein the at least one vent
opening comprises a plurality of perforations coincident with a
player's mouth.
6. The full-facemask of claim 1, wherein the facemask frame further
comprises a middle bar.
7. The full-facemask of claim 5, wherein the facemask frame further
comprises one or more vertical bars that extend between the middle
bar and the lower bar.
8. The full-facemask of claim 5, wherein the facemask frame further
comprises one or more vertical bars that extend between the upper
bar and middle bar.
9. The full-face helmet system comprising: a helmet, the helmet
comprises an outer shell; a facemask frame, the facemask frame
comprising an external surface and an internal surface, the
facemask frame comprising an upper bar and a lower bar; and a
reinforcement layer, the reinforcement layer coupled to the
external surface or internal surface of the facemask frame, at
least a portion of the reinforcement layer substantially matches
the shape of the facemask frame.
10. The full-face helmet system of claim 9, wherein the helmet
further comprises an impact mitigation layer, the impact mitigation
layer coupled to an inner surface of the outer shell.
11. The full-face helmet system of claim 9, wherein the helmet
further comprises an inner shell and an impact mitigation layer,
the impact mitigation layer disposed between the outer shell and
inner shell.
12. The full-face helmet system of claim 9, wherein the helmet
further comprises a stabilizer pad system, the stabilizer pad
system coupled to the outer shell.
13. The full-face helmet system of claim 12, wherein at least a
portion of the facemask frame is coupled to the stabilizer pad
system.
14. The full-face helmet system of claim 9, wherein the
reinforcement layer comprises a clear or transparent plastic
material.
15. The full-face helmet system of claim 9, wherein the at least
one vent opening comprises a plurality of openings.
16. The full-face helmet system of claim 9, wherein the
reinforcement layer further comprises a plurality of openings
adjacent to the at least one vent opening.
17. The full-face helmet system of claim 9, wherein the facemask
frame further comprises a middle bar.
18. The full-face helmet of claim 9, wherein the facemask frame
further comprises one or more vertical bars that extend between the
middle bar and the lower bar.
19. The full-face helmet of claim 9, wherein the facemask frame
further comprises one or more vertical bars that extend between the
upper bar and middle bar.
20. The full-face helmet of claim 9, wherein at least a portion of
the facemask frame protrudes into the at least one vent opening.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 62/981,701 entitled "Full Face Facemask," filed
Feb. 26, 2020, the disclosure of which are incorporated by
reference herein in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to methods, devices, and
systems for an improved helmet system with a full-face facemask.
More specifically, the improved helmet system includes a full-face
facemask to improve visibility and weight, but maintain impact
performance.
BACKGROUND OF THE INVENTION
[0003] Traditional football helmets have manufactured facemasks
with a plurality of metal bars to protect a player's face. The
facemask provides a way to protect the face while allowing for
limited visibility. Unfortunately, the more protection a player
would like (e.g., increased number of bars), the more the player's
visibility is reduced and the heavier it becomes. Also, the
plurality of bars provides other players the ease of grabbing the
facemask or otherwise restraining a player by grabbing the face
mask, which is illegal due to the risk of injury.
BRIEF SUMMARY OF THE INVENTION
[0004] The improved helmet system comprises a full-facemask that
combines the strength of a facemask with a reduced number of metal
bars and a polymer-based cover to allow for improved visibility,
safety and reduced weight, as well as potentially reduce the
players from grabbing onto the facemask to cause injury. The
polymer-based cover or reinforcement layer may be disposed over the
facemask frame for support and enhance impact performance.
[0005] In one embodiment, the full-face facemask comprising: a
facemask frame, the facemask frame comprising an external surface
and an internal surface, the facemask frame comprising an upper bar
and a lower bar; and a reinforcement layer, a portion of the
reinforcement layer coupled to the external surface or internal
surface of the facemask frame. At least a portion of the
reinforcement layer matches or substantially matches the shape of
the facemask frame. The reinforcement layer comprises a clear or
transparent plastic material. The reinforcement layer comprises at
least one vent opening, the at least one vent opening coincident
with a player's mouth. The at least one vent opening may include a
single opening or a plurality of openings coincident with a
player's mouth. The reinforcement layer further comprises a
plurality of perforations disposed adjacent to the vent opening.
the facemask frame further comprises a middle bar. The facemask
frame further comprises one or more vertical bars that extend
between the middle bar and the lower bar. The facemask frame
further comprises one or more vertical bars that extend between the
upper bar and middle bar.
[0006] In another embodiment, the full-face helmet system
comprising: a helmet, the helmet comprises an outer shell; a
facemask frame, the facemask frame comprising an external surface
and an internal surface, the facemask frame comprising an upper bar
and a lower bar; and a reinforcement layer, the reinforcement layer
coupled to the external surface or internal surface of the facemask
frame, at least a portion of the reinforcement layer substantially
matches the shape of the facemask frame. The helmet further
comprises an impact mitigation layer, the impact mitigation layer
coupled to an inner surface of the outer shell. The helmet further
comprises an inner shell and an impact mitigation layer, the impact
mitigation layer disposed between the outer shell and inner shell.
The helmet further comprises a stabilizer pad system, the
stabilizer pad system coupled to the outer shell. At least a
portion of the facemask frame is coupled to the stabilizer pad
system. The reinforcement layer comprises a clear or transparent
plastic material. The at least one vent opening comprises a
plurality of openings. The reinforcement layer further comprises a
plurality of openings adjacent to the at least one vent opening.
The facemask frame further comprises a middle bar. The facemask
frame further comprises one or more vertical bars that extend
between the middle bar and the lower bar. The facemask frame
further comprises one or more vertical bars that extend between the
upper bar and middle bar. The least a portion of the facemask frame
protrudes into the at least one vent opening.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0007] FIG. 1A depicts a side view of one embodiment of a Full-Face
Helmet System;
[0008] FIG. 1B depict a side view of one embodiment of a Full-Face
Helmet System;
[0009] FIGS. 2A-2C depict isometric and magnified views of an
alternate embodiment of a Full-Face Helmet;
[0010] FIGS. 3A-3E depict front views of different embodiments of
facemasks;
[0011] FIGS. 4A-4C depict various views of one embodiment of a
helmet;
[0012] FIG. 5 depicts an exploded view of one embodiment of a
helmet;
[0013] FIGS. 6A-6B depicts a cross-section of one embodiment of a
helmet comprising filaments undergoing local deformation;
[0014] FIGS. 7A-7B depicts a magnified cross-section of the helmet
of FIGS. 6A-6B; and
[0015] FIGS. 8A-8C depicts isometric views of alternate embodiments
of laterally supported filaments (LSF) structures.
DETAILED DESCRIPTION OF THE INVENTION
[0016] FIGS. 1A-1B and 2A-2C depicts side views of different
embodiments of a Full-Face Helmet System 10,30,32. The full-face
helmet system 10,30,32 comprises a helmet 12,78, a reinforcement
layer 14, a facemask or facemask frame 16. The helmet 12,78
comprises an outer shell. The helmet 12,78 further comprises an
impact mitigation layer, the impact mitigation layer coupled to an
inner surface of the outer shell. The helmet 12,78 further
comprises an inner shell and an impact mitigation layer, the impact
mitigation layer disposed between the outer shell and inner shell.
The helmet 12,78 further comprises a stabilizer pad system, the
stabilizer pad system coupled to the outer shell. The helmet 12,78
comprises a front region, a right region, a left region, a crown
region, a back region, and/or any combination thereof. Refer to
FIGS. 4A-4C for further helmet details.
[0017] The facemask frame 16 comprising an external surface and an
internal surface, the facemask frame 16 further comprising an upper
bar 28 and a lower bar 29. The upper bar 28 including a first
raised section, a second raised section and a central section, the
central section between a first and second raised section. Each of
the plurality of raised sections are raised relative to the central
section. The facemask frame 16 further comprises a middle bar 31,
the middle bar 31 disposed between the upper bar 28 and the lower
bar 29. The facemask frame 16 further comprises one or more
vertical bars 25 that extend between the middle bar 31 and the
lower bar 29. The least a portion of the facemask frame 16
protrudes into the at least one vent opening 18. The lower bar 29
and/or middle bar 31 is horizontal or substantially horizontal. At
least a portion of the facemask frame 16 is coupled to the
stabilizer pad system via a facemask connector 38. Alternatively,
the facemask frame 16 may be coupled to the outer shell via a
facemask connector 38. The different configurations of facemasks or
facemask frames shown in FIGS. 3A-3E.
[0018] The reinforcement layer 14 comprises a material, the
material is a clear or transparent plastic material. The material
may comprise a uniform thickness or a non-uniform thickness. The
thickness of the material may be based on the position-specific
player's needs. The material may further comprise a coating, the
coating may include an anti-reflective coating, a polarized
coating, a scratch resistant coating, an anti-fog coating, an
anti-microbial or anti-viral coating, an ultraviolet (UV)
protection coating, a photochromic coating, a tinted coating, a
mirror coating, a prescriptive coating or material and/or any
combination thereof.
[0019] The reinforcement layer 14 is coupled to the external
surface of the facemask frame 16 and/or the reinforcement layer 14
is disposed over the facemask frame 16, which a portion of the
internal surface of the reinforcement layer 14 contacts a portion
of the external surface of the facemask frame 16. Alternatively,
the reinforcement layer 14 is coupled to the internal surface of
the facemask frame 16, and/or the facemask frame 16 is disposed
over the reinforcement layer 14, which the internal surface of the
facemask frame 16 contacts a portion of the outer surface of the
reinforcement layer 14. Coupling to the different points on the
internal surface or the external surface of the facemask frame 16
allows the facemask frame 16 to support the reinforcement layer 14
in different regions to reduce or prevent the reinforcement layer
from deforming towards the player's face and/or it further provides
better distribution of the impact forces across the facemask frame
16. At least a portion of the reinforcement layer 14 substantially
matches the shape of the facemask frame 16. Alternatively, at least
a portion of the reinforcement layer 14 substantially matches one
or more contours of the facemask frame 16. In another embodiment,
the reinforcement layer 14 may be over molded to the external
surface or the internal surface of the facemask frame 16.
[0020] The reinforcement layer 14 comprises a body 22, a first
plurality of connecting members 26 and a second plurality of
connecting members 27. Each of the first or second plurality of
connecting members 26,27 located or disposed on the right and left
regions of the helmet 12 and/or body 22. The first plurality of
connecting members 26 extending outwardly from the body 22, the
plurality of connecting members 26 couple to or attach to a portion
of the outer shell of the helmet 10,30,32. Each of the first
plurality of connecting members 26 extending outwardly to couple to
or attach to the vent openings 15 or within the vent openings 15 on
the outer shell of the helmet 10,30,32. The second plurality of
connecting members 27 may couple or attach to the outer shell
and/or may couple or attach to the stabilizer pad system (not
shown). The first and/or the second plurality of connecting members
27 may comprise one or more openings, the one or more openings
sized and configured to receive a mechanical connector. The
mechanical connector may comprise a screw, a rivet, a dowel pin,
and/or any connectors known in the art.
[0021] The reinforcement layer 14 or the body 22 comprises at least
one vent opening 18. The at least one vent opening 18 comprises a
plurality of openings (not shown) or a single vent opening. The at
least one vent opening 18 comprises a shape, the shape includes a
circle, an oval, a regular polygon and/or an irregular polygon. The
shape may further include a "U" shape, "D" shape, a hemispherical
shape, or an arch shape. The reinforcement layer 14 further
comprises a plurality of openings 20 adjacent to the at least one
vent opening 18. The plurality of openings 20 including a width
smaller than the at least one vent opening width. The at least one
vent opening 18 may be coincident or aligned with a player's mouth.
Alternatively, the at least one vent opening 18 may be in front of
the player's mouth. At least a portion of the facemask frame 16
protrudes or extends into or through the at least one vent opening
18. The top portion of the body 22 of the reinforcement layer 14
may be coupled to the front bumper 34 located in the front region
of the helmet 10,30,32. Mechanical connectors may be inserted into
the one or more openings 40 of the reinforcement layer 14 disposed
at the top region of the reinforcement layer 14 or the body 22.
[0022] Accordingly, the bottom portion of the body 22 of the
reinforcement layer 14 may be coupled using one or more bumper
connectors 36. The one or more bumper connectors 36 comprises a
first portion and a second portion. The first portion comprises
longitudinal members 42, the longitudinal members 42 extending
perpendicularly or normal from the first portion. The longitudinal
members 42 being inserted into a plurality of holes 44 on the
reinforcement layer 14 and connected to second portion of the one
or more bumper connectors 36. The one or more bumper connectors 36
may comprise a plastic, foam, an elastomeric foam, rubber, and/or
any material that facilitates the absorption of impacts and/or
vibrations.
[0023] The reinforcement layer 14 may further comprise one or more
ribs (not shown). The one or more ribs are disposed onto the
external surface or internal surface of the reinforcement layer.
The one or more ribs extend away from the external or internal
surface of the reinforcement layer. Alternatively, the one or more
ribs extend perpendicularly or substantially perpendicular from the
external or internal surface of the reinforcement layer 14. The one
or more ribs having a length and a width. The one or more ribs may
have a horizontal orientation or a vertical orientation. In one
embodiment, If the one or more ribs are in a vertical orientation,
the one or more ribs sized and configured to fit within the
entirety of the spacing of the one or more vertical bars 62,70
and/or at least a portion of the spacing of the one or more
vertical bars 62,70. The one or more ribs may have a horizontal
orientation or a vertical orientation.
[0024] FIGS. 3A-3E depicts various embodiments of facemasks or
facemask frames, 46, 66, 72, 74, 76 that may be used with the
full-face helmet system or full-face facemask. The facemasks or
facemask frames 46,66,72,74,76 comprise a top portion 48, a middle
portion 50 and a lower portion 52. The top portion 48 may be
coupled to the helmet. The middle portion 50 includes the field of
view for the player. The lower portion 52 includes different bar
configurations to protect the nose, and lower half of the face of
the player.
[0025] The facemasks or facemask frames 46, 66, 72, 74, 76
comprises an upper bar 54 and a lower bar 60. The facemask or
facemask frames 46,66, 72,74 76 may further comprise a middle bar
58. The upper bar 54 includes a first raised section, a second
raised section and a central section, the central section between a
first and second raised section. Each of the plurality of raised
sections are raised relative to the central section. The facemasks
or facemask frames 46, 66, 72, 74, 76 further includes a first
intermediate bars 56 and a second intermediate bar 68. The first
intermediate bar 56 is spaced apart from the upper bar 54 to create
a space or an opening. The first intermediate bar 56 is horizontal
or substantially horizontal. One or more connecting elements 64 may
be disposed within the space or opening below the central section
to couple the upper bar 54 to the intermediate bar 56.
Alternatively, the first intermediate bar 56 and the second
intermediate bar 68 can be disposed between the upper bar 54 and
the middle bar 58.
[0026] The facemasks or facemask frames 46,66,72,74,76 may further
one or more vertical bars 62,70. The one or more vertical bars
62,70 may extend between the first intermediate bar 56 and the
middle bar 58. The one or more vertical bars 62,70 may extend
between the middle bar 58 and the lower bar 60. The one or more
vertical bars 62,70 may extend between the first intermediate bar
56 and middle bar 58 and extend between the middle bar 58 and the
lower bar 60. Each of the one or more vertical bars 62,70 are
spaced apart from the adjacent one or more vertical bars 62,70 to
create a space. The one or more vertical bars 62,70 that extend
between the first intermediate bar 56 and the middle bar 58 are
offset or are not aligned with the one or more vertical bars 62,70
that extend between the middle bar 58 and the lower bar 60.
[0027] FIGS. 4A-4B depicts various views of one embodiment of a
helmet 78. The helmet 78 comprises a front region, a right region,
a left region, a crown region, a back region, and/or any
combination thereof. The helmet 78 comprises an outer shell 86. The
helmet 78 further comprises an impact mitigation layer 94, the
impact mitigation layer 94 coupled to an inner surface of the outer
shell 86. The helmet 78 further comprises an inner shell 96, the
impact mitigation layer 94 disposed between the outer shell 86 and
inner shell 96. The helmet 78 further comprises a removable
stabilizer pad system 88, the stabilizer pad system 88 coupled to
the right and left regions of the outer shell 86. The helmet 78 may
further comprise a plurality of pad assemblies that are attached or
coupled to an inner surface of the helmet 78 and/or an inner
surface of the inner shell 96. The plurality of pad assemblies
comprises at least a portion of a surface that contacts the
player's head. The helmet 78 may further comprise different
accessories, including a visor, chincups with straps and different
facemask or facemask frame configurations.
[0028] The outer shell 86 is constructed from a flexible plastic
material that desirably permits significant local deformation 106
when impacted with a sufficient external force as shown in FIGS. 6B
and 7B. The outer shell 86 comprises a generally spherically shaped
body with complex contours on an upper portion thereof, which
defines a pair of medial 80 and lateral 82 raised bands that extend
from the front region towards the back region of the outer shell 86
with a centrally positioned recessed band between the medial 80 and
lateral 82 raised bands. The outer shell 86 further includes a
plurality of vent holes 84,90 (i.e., perforations in the outer
shell which allow gases to pass through the shell body), and an ear
hole on each side of the outer shell 86 to allow sound transmission
to the wearer's ears. Accordingly, the outer shell 86 includes a
raised side band 92 that extends from the edge of the outer shell
86 towards the back region. The outer shell 86 includes a raised
side band 92 that extends from the edge of the outer shell 86 in an
upwardly direction towards the back region.
[0029] The impact mitigation layer 94 comprises a plurality of
deformable structures positioned inside of and mechanically
fastened to inner surface of the outer shell 78, which prevents
relative movement between the impact mitigation layer 94 and the
outer shell 86. The impact mitigation layer 94 comprises a
plurality of impact mitigating structures, the plurality of impact
structures comprises at least one of a plurality of filaments (not
shown), a plurality of laterally supported filaments (LSFs) (not
shown), a plurality of undulated structures (not shown) and/or a
foam layer (not shown).
[0030] In one embodiment, the impact mitigating structures can
comprise a plurality of filaments 102 as shown in FIGS. 6A-6B and
7A-7B. The plurality of filaments 102 may be thin, longitudinally
extending members or be shaped and configured to deform
non-linearly in response to an impact force. The plurality of
filaments 102 may comprise an aspect ratio of 3:1 or greater, which
the height is greater than the width. The non-linear deformation
behavior is expected to provide improved protection against
high-impact forces, and/or oblique forces. The non-linear
deformation behavior is described by the filaments stress-strain
profile. The non-linear stress-strain profile illustrates that
there can be an initial rapid increase in force (region I) followed
by a change in slope that may be flat, decreasing or increasing
slope (region II), followed by a third region with a different
slope (region III).
[0031] The filaments undergo a buckling response 104 to an incident
force, where buckling 104 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 plurality
of filaments 102 may be configured to deform elastically, allowing
the at least a portion of the filaments 102 to substantially return
to their initial configuration once the external force is removed.
The at least a portion of filaments 102 may extend between two
surfaces, the at least a portion of filaments having at least one
end coupled to the outer layer and/or the inner layer. The
plurality of filaments 102 may include be solid or hollow.
[0032] In another embodiment, the impact mitigating structures can
comprise a plurality of laterally supported filaments (LSF)
structures 108,110,112 as shown in FIGS. 8A-8C. The LSF structures
108,110,112 comprise a plurality of filaments 102 that are
interconnected by laterally positioned walls or sheets 114 in a
polygonal configuration. Polygonal structures and/or configurations
known in the art may be contemplated, including triangular, square,
pentagonal, hexagonal, septagonal, octagonal, and/or any
combination thereof. A plurality of sheets or lateral walls 114 can
be secured between adjacent pairs of filaments 102 with each
filament 102 having a pair of lateral walls 114 attached thereto.
Alternatively, each of the plurality of filaments 102 may comprise
a lateral wall 114 extending outwardly therefrom to at least one
adjacent filament 102. In the disclosed embodiment, the lateral
walls 114 can be oriented approximately 120 degrees apart about the
filament axis, with each lateral wall 114 extending substantially
along the longitudinal length of the filament 114. The plurality of
LSF structures 108,110,112 can be arranged in one or more rows or
in an array, each of the one or more rows may be aligned or offset.
The impact mitigation structures may comprise a plurality of LSF
structures 108,110,112 and a base layer, the plurality of LSF
structures 108,110,112 disposed on the base layer and spaced apart.
The impact mitigation structures may comprise a plurality of LSF
structures 108,110,112, a first base layer and a second base layer,
the plurality of LSF structures 108,110,112 spaced apart and extend
between the first and second base layer.
[0033] Accordingly, the orientation of the lateral walls 114 may be
asymmetric, which at least one lateral wall 114 may be oriented
approximately 75 to 135 degrees apart about the filament 102 axis.
The shape, wall thickness or diameter, height, and configuration of
the lateral walls 114 and/or filaments 102 may vary to "tune" or
"tailor" the structures to a desired performance. For example, one
embodiment of a polygonal LSF structure 108,110,112 may have a
tapered configuration as shown in FIG. 8A. The polygonal LSF
structure 108,110,112 can have a top surface and a bottom surface,
with the bottom surface perimeter (and/or bottom surface
thickness/diameter of the individual elements) that may be larger
than the corresponding top surface perimeter (and/or individual
element thickness/diameter). In another example, the polygonal LSF
structure 108,110,112 can have an upper ridge or upper plate 116.
The upper plate 116 is planar and extends across to the adjacent
filament 102. The upper plate 116 contacts at least one end of the
plurality of filaments 102 and/or each of the plurality of
filaments 102. The upper plate 116 may further comprise an opening.
The upper plate 116 may comprise a solid material or hollow
material. The upper plate 116 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 polygonal
element).
[0034] In another embodiment, the impact mitigation layer may
further comprise at least one foam layer or a portion of a foam
layer (not shown). 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 (e.g.,
VN600),), Ethylene Vinyl Acetate foam (EVA), Ariaprene foam, latex
rubber foam, convoluted foam ("egg create foam"), Evlon foam,
impact hardening foam, 4.0 Custula comfort foam (open cell low
density 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.
[0035] The helmet 78 further comprises an inner shell 96. The inner
shell 96 is constructed from a rigid or relatively rigid plastic
material. The inner shell 96 that is more rigid than the outer
shell 86 material. The inner shell 96 is also mechanically secured
to various portions of the impact mitigation layer to prevent
relative movement between the inner shell 96 and the impact
mitigation layer 94. The inner shell 96 further comprises a
plurality of openings, into which various attachment assemblies of
the plurality of pad assemblies are securely attached.
[0036] The helmet 78 further comprises a plurality of pod
assemblies that are removably coupled to the inner surface of the
inner shell 96. The plurality of pod assemblies includes
multi-layered foams (e.g., an impact foam layer and a comfort foam
layer) that sizes the helmet 78 to the wearer's head and also
provides additional impact protection and comfort. The plurality of
pod assemblies comprises a first material layer, a second material
layer, one or more foam layers and a connection mechanism. The
first material layer and/or the second material layer may comprise
a 2-way stretch material, a 4-way stretch material, and/or a foam
layer. Additionally, the first material layer and/or the second
material layer may further comprise a polymeric material, such as
polypropylene, polyethylene, polyester, nylon, PVC, PTFE, and/or
any combination thereof. Furthermore, the first material and/or the
second material layer may be breathable and wick away moisture
easily from the skin while carrying out various sporting and
athletic activities. The first material layer may be the same or
different than the second material layer. The one or more foam
layers are disposed between the first and second material layer. At
least a portion of the connection mechanism is disposed between the
first and second material layer.
[0037] The one or more pad assemblies can be modular and removably
coupled into any configuration within the helmet 78. Each of the
one or more pod assemblies may be positioned proximate to an
adjacent to the one or more pad assemblies, such that the perimeter
of each of the one or more pad assemblies may be parallel to the
adjacent one or more pod assemblies. The plurality of liner pad
assemblies may include regions such as one or more of the
following: a frontal assembly (or front), an occipital assembly (or
lower-back), a mid-back assembly (right and/or left sides), a
parietal assembly (or midline), and a temporal assembly (right
and/or left sides), and/or any combination(s) thereof.
[0038] The plurality of pad assemblies can comprise a generally
triangular shaped body with rounded corners (an isosceles triangle,
for example), although a variety of other shapes, including other
shaped triangles, squares, pentagons, hexagons, septagons and/or
octagon shapes, could be utilized in a variety of embodiments. In a
similar manner, alternative shapes having rounded and/or sharp
corners and/or edges may be utilized, as well as irregular and/or
re-entrant shaped bodies, if desired. The plurality of pad
assemblies can be provided in a series of sizes and/or thicknesses,
including a 1/4'' thickness progressively up to 1'' or 1.25'' or
greater thickness. Desirably, the different thickness triangular
pods bodies can be provided with similar external dimensions (i.e.,
height and/or width), with only the thickness differing to any
substantial degree, allowing different thickness pods to be "mixed
and matched" for use with a single helmet liner or other component,
and/or other item of protective clothing.
[0039] The helmet 78 further comprises a stabilizer system 88. The
stabilizer system 88 comprises at least two different pad
assemblies that are positioned on the right and left regions of
outer shell 86. The stabilizer system 88 includes a bridge pad
assembly and a stabilizer pad assembly. A bridge pad assembly is
secured to an inner surface of the outer shell 86 adjacent to and
below the ear hole on the right and left sides, and a stabilizer
pad assembly is secured to an inner surface of the outer shell 86
at locations forward of the ear hole. The stabilizer pad assemblies
are available in different thicknesses-0.5 inch or greater; 1.0
inch or greater; or 0.5 inch to 2 inches. Portions of the
stabilizer pad assembly desirably project forwardly to protect
various regions of the wearer's skull, which can include portions
of the zygoma (cheek bone), portions of the maxilla and portions of
the mandible (e.g., the coronoid process, the condyle, and a
portion of ramus) of the wearer. Each of the stabilizer pad
assemblies are mounted to the stabilizer plates. Each stabilizer
plate also includes a facemask mount which secures and couples to a
lower attachment point on the facemask or facemask frame. Each of
the stabilizer pad assembly and the bridge pad assembly comprises a
plate and one or more foam layers, the one or more foam layers
coupled to the plate.
[0040] The helmet 78 may further comprise one or more facemask clip
styles or facemask bumper styles--a standard facemask clip and a
quick release facemask clip. The standard facemask clip requires
tooling for placement and removal. However, the quick release
facemask clip requires limited tooling for placement and easy,
repeatable manual release. The helmet 78 can further include a
variety of accessories, including a visor and/or a chincup/strap.
The chincup can be a standard chincup that is known in the art.
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