Full-Flex Helmet System

Abstract

A multi-sectional helmet for reducing the impact of force sustained in sporting, construction, military, motorized vehicle, and other activities where the impact of force applied to the head must be mitigated. Planar compression springs between helmet sections generate gaps between sections for distribution of force from external impact as springs compress and bend radially, permitting movement of sectional parts toward and away from one another. The number of springs and spring parameters as well as the number and arrangement of helmet sections may be modulated to optimize the distribution of force. The ends of compression springs are anchored to adjacent helmet sections, and material extending from one helmet section and overlapping the adjacent helmet section prevents exposure of the interior of the helmet to the elements.

Description

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention is directed generally to a protective helmet, and more particularly to improvements to a novel helmet utilizing spring-based interconnected sections and other engineering mechanisms for dispersion of applied force and reduction of localized impact from contact events.

Technology in the Field of the Invention

Since the first plastic football helmet was introduced in 1939, helmet design has been a source of constant technological innovation with the dual goals of increasing athletic performance and reducing traumatic head injuries. Modern football helmets feature innovative designs in two primary areas: head coverings and facemasks. The plethora of available football helmet designs are driven in part by a lack of football organization restrictions. For instance, the National Football League (NFL), the most popular professional football sports league in the United States, sets mostly cosmetic standards for only chinstraps and facemasks. The following non-essential publication is incorporated by reference in its entirety to aid in the understanding of helmet design over time: Stamp, Jimmy. “Leatherhead to Radio-head: The Evolution of the Football Helmet.” Smithsonian Magazine. Smithsonian Institution. 1 Oct. 2012. Web. 14 Nov. 2019.

Sports-related head injuries have become a major topic of discussion over the past few years due to new research that details long-term consequences of multiple concussions, also known as mild traumatic brain injuries (mTBIs). Annually, over 40,000 hospital emergency department visits for concussion are attributable to sports participation. Youth hockey and football players are particularly susceptible to concussion. The following non-essential publications are incorporated by reference to aid in the understanding of sports-related concussions among youth: Zhao, Lan et al. “Statistical Brief #114, Sports Related Concussions, 2008.” H-CUP: Healthcare Cost and Utilization Project. Agency for Healthcare Research and Quality. May 2011. Web. 14 Nov. 2019; Guskiewicz, K. M. et al. “Epidemiology of Concussion in Collegiate and High School Football Players.” Am. J. Sports Med. 2000; 28:643-650. Brazarian, J. J. et al. “Mild Traumatic Brain Injury in the United States, 1998-2000.” Brain Inj. 2005; 19(2):85-91; Halstead, M. E. et al. “Sport-Related Concussion in Children and Adolescents.” Pediatrics. 2018; 142(6).

Beyond concussions, traumatic brain injury (TBI) might occur in sports settings when an external force applied to the head or body causes the recipient's brain to move relative to his or her skull. Categorically, these movements are measured in terms of linear and angular force responses. These rotational forces in multiple directions are key contributors to long-term brain injury, and repeat injury leads to chronic traumatic encephalopathy (CTE), a neurodegenerative disease. The following non-essential publication is incorporated herein by reference to aid in understanding of angular and linear biomechanics and implications for the design of types of sports helmets: Smith, T. A. et al. “Angular Head Motion With and Without Head Contact: Implications for Brain Injury.” Sports Engineering. 2015; 18:165.

Football players at the NFL and college levels are being introduced to new concussion protocols driven by testing data, such as the HITS from Virginia Tech University. HITS is notable because it confirms that athletes are sustaining significant head impacts worthy of innovation in the industry—whether the sport be football, hockey, or baseball. In Analysis of Real-time Head Accelerations in Collegiate Football Players, Duma and Manoogian conclude that the HIT system and its helmet-mounted accelerometer were able to effectively record thousands of head-impact events—and they suggested the system be integrated with existing clinical procedures to evaluate athletes on the sidelines.

Action is being taken at various levels of American football to reduce the frequency of concussions in order to protect players. Methods include implementation of concussion protocols at the highest levels of play, modification of practices to include fewer high-impact drills, consideration by various state legislatures of the risks and reactions to head injuries, and innovation in the helmet industry. The following non-essential publication is incorporated by reference to aid in the understanding of this national imperative: National Center for Injury Prevention and Control, “Report to Congress on Mild Traumatic Brain Injury in the United States: Steps to Prevent a Serious Public Health Problem,” Centers for Disease Control and Prevention, Atlanta, Ga., 2013.

Due to advances in materials science and computerized modeling as well as awareness of the high incidence of sports-related TBIs, helmet manufacturers are continually and effectively innovating upon the standard single-mold, dome-shaped sports helmet design. Newly introduced helmet designs incorporate energy-absorbing materials, geometric shell patterns, or even plate-like movable shells, and are tested extensively to quantify performance characteristics by simulating head impacts in the laboratory. The following non-essential publication is incorporated by reference to aid in the understanding of testing methods instituted by the National Operating Committee on Standards for Athletic Equipment (NOCSAE): Gwin, J. T. et al. “An Investigation of the NOCSAE Linear Impactor Test Method Based on In Vivo Measures of Head Impact Acceleration in American Football.” J. Biomech. Eng. 2010; 132(1).

These approaches, while improvements in their own right, do not capture the benefits introduced by the present invention's re-conceptualization of the fundamental sports helmet design. The present invention provides a multi-sectional helmet with planar compression springs serving as connectors and constraints for the multiple sections. The present invention pertains to newly disclosed and unique designs in the present inventors' helmet system, the claimed priority of which was disclosed in U.S. Non-provisional patent application Ser. No. 15/985,690, titled “Full-Flex Helmet System,” filed May 21, 2018.

The inventors' prior disclosure, while presenting their fundamental innovations, failed to suggest certain useful designs described by the present invention. In the inventors' prior disclosure, compression springs were wrapped around bolts attached to housing strips along adjacent sectional parts, wherein the bolts were further anchored immovably at one end to one sectional part and anchored movably at the other end to the adjacent sectional part, thus allowing for compression and extension of the spring and sliding of the spring along the bolt. The newly disclosed system introduces the potential for original manufacturing processes and has exhibited optimized helmet impact force dispersion, specifically by modulation of spring parameters and spring attachment to the helmet's sectional parts, as well as by enablement of spring bending radially toward the center of the helmet.

It is the objective of the present disclosure to enable through descriptive teaching the method of manufacture and system design of a novel multi-sectional helmet with superior impact dispersion performance to previous helmet designs.

BRIEF SUMMARY OF THE INVENTION

In one exemplary embodiment of the present invention, a multi-sectional helmet is provided with planar compression springs serving as sectional connectors and constraints between adjacent sectional parts, generating gaps between these sectional parts. In this embodiment, an off-the-shelf polycarbonate helmet has been cut into sections and re-attached by arrays of springs. In first and second preferred embodiments, respectively, the helmet is sectioned into fifths and fourths.

In another embodiment of the present invention, a multi-sectional helmet is assembled from sectional parts specifically designed as sectional parts.

In these or additional embodiments, presently-marketed helmet shell materials could be utilized. The shell could consist of a purely polycarbonate material, or could incorporate other advanced, lightweight and high-strength materials. In these or additional embodiments, gaps between sectional parts can be covered by flanged material extending from one sectional part and overlapping the adjacent sectional part to prevent exposure of the interior of the helmet to the elements.

The main purpose of the present invention is to reduce the impact of force sustained through construction, military, or sporting events to include operation of motorcycles, all-terrain vehicles, and other motorized vehicles. Furthermore, the present invention may be applied as a medical intervention to protect individuals prone to falling. The invention provides increased safety to the user-wearer, and is distinguishable over the present state of the art, including, but not limited to: single mold shells with internal padding, including those shells made of energy-absorbing materials; layered shells; plate-like shells where external layers that glide over internal layers; shells with arrays of spine structures; and shells with columnar springs and other compression devices.

Upon direct impact with an oppositely moving external force along the exterior of the present invention, the helmet directs an impact force back outwards and around the perimeter of the interconnected sections. The same impact-reducing mechanism is activated in response to a fall or body contact that angles or turns the user-wearer's head into a solid object.

It is an object of the present invention to improve recent advances in helmet materials and shape by means of a new system introducing enhanced performance and safety benefits from the novel design.

It is another object of the present invention to provide a new safety helmet for use in sporting, construction, military, motorized vehicle, and medical endeavors through original marketing and manufacture.

BRIEF DESCRIPTION OF THE DRAWINGS

The unique attributes of the multi-sectional helmet are presented in detailed embodiments below. Chiefly, the apparatus described in this application is designed to optimally disperse, and thus blunt, force of impact sustained to its external shell. In doing so, the apparatus may present performance and safety benefits to its wearer over alternative helmet designs. The present invention will be better understood from the following detailed description with reference to the following drawings:

FIG. 1 is a top plan view of a first embodiment of the multi-sectional helmet of the present invention.

FIG. 2 is a bottom view of the multi-sectional helmet depicted in FIG. 1 showing the interior of the helmet.

FIG. 3 is a side view of the multi-sectional helmet depicted in FIG. 1.

FIG. 4 is a front view of the multi-sectional helmet depicted in FIG. 1.

FIG. 5 is an interior view of the left front of the multi-sectional helmet depicted in FIG. 1 from the perspective of the wearer of the helmet.

FIG. 6 is a top plan view of a second embodiment of the multi-sectional helmet of the present invention.

FIG. 7 is a bottom view of the multi-sectional helmet depicted in FIG. 5 showing the interior of the helmet.

FIG. 8 is an enlarged bottom view of the interior of the multi-sectional helmet depicted in FIG. 5 showing the point where all four sectional parts of the helmet are joined together.

FIG. 9 is a front view of the multi-sectional helmet depicted in FIG. 5.

FIG. 10 is a top front view of the multi-sectional helmet depicted in FIG. 5 showing the facemask attached.

FIG. 11 is an interior view of the right side of the multi-sectional helmet depicted in FIG. 5 from the perspective of the wearer of the helmet.

FIG. 12 is an interior view of the right side of the multi-sectional helmet depicted in FIG. 5 from the perspective of the wearer of the helmet wherein interior padding has been inserted into the helmet.

FIG. 13 is an enlarged side view of an embodiment of the isolated spring used for bridging gaps between sectional parts of the multi-sectional helmet, wherein a cap is affixed to one end of the spring.

FIG. 14 is an enlarged schematic representation of a cross-sectional view of a closed gap between adjacent sectional parts of an embodiment of the multi-sectional helmet of the present invention.

FIG. 15 is an enlarged schematic representation of a cross-sectional view of an open gap between adjacent sectional parts of an embodiment of the multi-sectional helmet of the present invention.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

As depicted in FIG. 1 and FIG. 2, in this first exemplary embodiment a helmet is segmented into five sectional parts 20A, 20B, 22A, 22B, 22C meeting at junction 21 at the apex of the wearer's head and contoured around the side, back, and top circumference of the wearer's head. Of the sectional parts 20A, 20B, 22A, 22B, 22C, the sectional parts 20A, 20B are frontal and the sectional parts 22A, 22B, 22C are rear. The sectional parts may include one or more depressions or vents, for example 24A, 24B.

FIG. 2 shows the sectional parts 20A, 20B, 22A, 22B, 22C evenly spaced away from each other by gaps 28, 29 by planar arrays of uniform-width springs 32 which are securely attached on the interior of the helmet at endpoints, for example 34A, 34B. The springs 32 use tempered high-carbon steel, also referred to as music or piano wire; these springs exhibit high tensile strength and fatigue life, are designed to withstand high load stress, and are ideal for cyclic load stresses. Alternative spring embodiments anticipated herein include springs using stainless steel, alloy steel, carbon steel (including low-, medium-, and high-carbon), and any other material suitable for manufacture of compression springs. Furthermore, alternative embodiments anticipated herein might feature non-uniformity with respect to spring width, for instance with wider springs at the base of the helmet compared to the apex. The spring array and attachment design generates gaps, for example 28, 29, between pairs of adjacent sectional parts, for example 20A, 20B for gap 28 and 22A, 22B for gap 29, which may be covered by material, for example 30 for gap 28 and 31 for gap 29, extending from one sectional part and overlapping the adjacent sectional part within the helmet interior. Alternative embodiments anticipated herein might feature material illustrated by 30, 31 on the exterior of the helmet instead of the interior, serving the same protective purpose. Here, gaps 28, 29 generated by an array of springs anchored immovable at their ends are covered by interior material 30, 31 extending from sectional parts 20B, 22B and overlapping adjacent sectional parts 20A, 22A, preventing exposure of the interior of the helmet to the elements. The material 30, 31 could, but need not be limited to the same material makeup as the helmet shell. The material 30, 31 could also be adhesively bound to the helmet or manufactured as sectional flange ends.

As an example of springs anchored immovable at their ends between sectional parts, spring 32 is anchored by adhesive 34A, 34B to sectional parts 22A, 22B. In this embodiment, fasteners 26 (FIG. 1) penetrate sectional parts 20A, 20B, 22A, 22B, 22C radial to the wearer's head, and for spring 32 these fasteners also penetrate attachment strips 36A, 36B so that adhesive 34A, 34B anchors spring 32 to both attachment strips 36A, 36B and the fasteners. The adhesive, both the spring adhesive 34A, 34B and adhesive for attaching the material 30, 31, used in this exemplary embodiment is an off-the-shelf epoxy, but in mass production might include an industrial cement, cyanoacrylate, adhesive tape, ultrasonic welding, or any other bonding agent or device demonstrated effective in the sporting, construction, military, motorized vehicle, or medical industries.

Referring now to FIG. 3, a side view of this embodiment is presented. Gap 38 between frontal sectional part 20A and rear sectional part 22A is formed by an array of springs anchored immovable at their ends between sectional parts 20A, 22A. Gap 38 is covered by material 40 extending between the adjacent sectional parts 20A, 22A. As an example of springs anchored immovable at their ends between sectional parts, spring 42 spaces away adjacent sectional parts 20A, 22A and is partially visible through ear cavity 44A.

In FIG. 4, a front view of this embodiment is presented. Gap 28 between adjacent frontal sectional parts 20A, 20B is formed by an array of springs anchored immovable at their ends between sectional parts 20A, 20B, and gap 28 is covered by material 30 extending between the adjacent sectional parts 20A, 20B. Rear sectional parts 22A, 22B, 22C are visible through the interior of the helmet, and ear cavities 44A, 44B are situated to optimize hearing for the wearer.

In FIG. 5, an interior view from the perspective of the wearer of the helmet of the left front of this embodiment depicts spring 32 bridging the gap between sectional parts 22A,22B, anchored to attachment strips 36A, 36B at both ends by adhesive 34A, 34B.

Referring now to FIG. 6 and FIG. 7, an alternative exemplary embodiment of the present invention is a helmet segmented into four sectional parts 60, 62A, 62B, 64 meeting at junction 80 at the apex of the wearer's head and contoured around the side, back, and top circumference of the wearer's head. Of the sectional parts 60, 62A, 62B, 64, the sectional part 60 is frontal, sectional parts 62A, 62B are side, and sectional part 64 is rear. The frontal sectional part 60 may include one or more depressions or vents, for example 66A, 66B. The sectional parts 60, 62A, 62B, 64 are spaced away from each other by arrays of springs 74, generating gaps between pairs of adjacent sectional parts which may be covered by material extending from one sectional part and overlapping the adjacent sectional part. For example, gap 68 is generated by an array of springs anchored immovable at their ends between sectional parts 60, 62A, and material 70 extends from sectional part 60 and overlaps adjacent sectional part 62A, covering gap 68 to prevent exposure of the interior of the helmet to the elements. As an example of springs anchored immovable at their ends between sectional parts, spring 74 is anchored by adhesive 78A, 78B to attachment strip 76 and material 70 which are affixed to sectional parts 60, 62A.

In FIG. 8 an enlarged bottom view of the interior of this embodiment depicts junction 80 at the apex of the wearer's head where sectional parts 60, 62A, 62B, 64 are joined together.

In FIG. 9, a front view of this embodiment is presented. Gap 98 between adjacent sectional parts 62A, 64 is formed by an array of springs anchored immovable at their ends between sectional parts 62A, 64, and gap 98 is covered by material 90 extending between the adjacent sectional parts 62A, 64. Rear sectional part 64 is visible through the interior of the helmet, and ear cavities 72A, 72B are situated to optimize hearing for the wearer.

As depicted in FIG. 10, facemask 100 has been attached to this embodiment, such that impact to any one of sectional parts 60, 62A, 62B, 64 or facemask 100 causes any combination of spring compression, spring bending radially toward the center of the helmet, and movement of one or more sectional parts towards and away from one another, thereby distributing force by external impact.

In FIG. 11, the interior view of the right side of this embodiment is depicted from the perspective of the wearer of the helmet showing arrays of springs generating gaps between pairs of adjacent sectional parts 60, 62A, 62B, 64. As an example of springs anchored immovable at their ends between sectional parts, spring 74 is anchored by adhesive 78A, 78B to attachment strip 76 and material 70 which are affixed to sectional parts 60, 62A. In FIG. 12 an enlarged view of this region depicts the interior of the helmet after covers 120 have been installed over springs and padding 122 has been installed throughout the helmet interior.

Referring now to FIG. 13 and FIG. 14, an embodiment of the present invention comprises caps 132A, 132B affixed to either end of spring 130 for installation into the multi-sectional helmet. In FIG. 13 an enlarged side view of spring 130 depicts attachment of cap 132A to an end of spring 130 wherein the end of cap 132A that fits inside spring 130 is threaded to facilitate joining of spring 130 and cap 132A. In an alternative embodiment, the end of cap 132A that fits inside spring 130 is smooth and fits tightly within spring 130 upon installation. FIG. 14 depicts installation of spring 130 between sectional parts 134A, 134B of an embodiment of the present invention, with caps 132A, 132B affixed to both ends of spring 130. Installed, these caps 132A, 132B facilitate the anchoring of the springs by adhesive attachment, for example 34A, 34B (FIG. 2). In another embodiment, caps 132A, 132B are threaded at their ends distal to spring 130 to facilitate anchoring of the springs by screwing caps 132A, 132B into adjacent sectional parts using Phillips, slotted, hex, Torx, or any other screw drive. In FIG. 14 force vector 140 depicts force from external impact applied in the direction from sectional part 134B toward sectional part 134A, compressing spring 130 and closing the gap between sectional parts 134B, 134A. Material 136 extending from sectional part 134B overlaps sectional part 134A both in the presence and absence of external force in order to prevent exposure of the interior of the helmet to the elements.

In FIG. 15, another embodiment of the present invention comprises fasteners 152A, 152B planar to the wearer's head anchored by adhesive 158A, 158B to sectional parts 154A, 154B, anchoring immovably spring 150 at both of its ends to sectional parts 154A, 154B. In this depiction, no force from external impact is applied, thus gap 160 spaces sectional parts 154A, 154B away from each other and material 156 extends from sectional part 154B to overlap sectional part 154A to prevent exposure of the interior of the helmet to the elements.

Two embodiments of the present invention, namely helmets segmented into five and four sections, were subjected to the NOCSAE Pneumatic Ram Impact tests (section 5.2). These tests were conducted under NOCSAE DOC (ND) 002-17m19 “Standard Performance Specification for Newly Manufactured Football Helmets.” After the required system checks were conducted, the Pneumatic Ram Impact tests were conducted on each embodiment, impacting the helmet at the following six locations: Side, Rear Boss NC, Rear Boss CG, Rear, Front Boss, and Random. The Random location tested for both embodiments was 7°, −135°, 42.67 mm above the basic plane, and 28.64 mm right of the rear midsagittal plane. During impact, resultant peak rotational acceleration experienced by the test headform was measured in radians per second squared (rad/s²), and Severity Index (SI) values were also measured.

For a first embodiment comprising five sections, peak rotational accelerations for the six locations were 5011, 3992, 3378, 3320, 5436, and 2400 rad/s², respectively, and SI values for the six locations were 134, 123, 199, 187, 128, and 206, respectively. For a second embodiment comprising four sections, peak rotational accelerations for the six locations were 4358, 2646, 2829, 3278, 5124, and 2742 rad/s², respectively, and SI values for the six locations were 120, 92, 200, 191, 137, and 212, respectively. These data demonstrate acceptable resultant peak rotational acceleration experienced by the test headform during impact, as well as acceptable SI values. Thus, these two embodiments of the present disclosure exhibited optimized helmet impact force dispersion.

Throughout this specification and the claims, the term “spring parameters” includes parameters of compression springs, including outside diameter, inner diameter, mean diameter, free length, wire diameter, index, solid height, active coils, pitch, rate, and handedness. The term “adhesive” includes glue, resins, epoxies, industrial cement, adhesive tape, ultrasonic welding, non-reactive and reactive adhesives, and any other bonding agent or device. The term “radial fasteners” is used for fasteners penetrating sectional parts radial to the wearer's head, and includes screws, nails, staples, bolts, pins, and rivets. The term “planar fasteners” is used for fasteners in plane with the wearer's head, and includes screws, nails, staples, bolts, and pins. The terms “overlap” and “overlapping” include extending over, extending under, and extending both over and under to cover partly.

Claims

1. A safety helmet having sectional components, segmented for the distribution of force from external impact, said safety helmet comprising: a plurality of sectional parts contoured beside the side, back, and top circumference of the wearer's head when it is worn; anda plurality of springs between said sectional parts and oriented planar to the wearer's head when it is worn;wherein said sectional parts are spaced away from each other by said springs, generating gaps between sectional parts that are adjacent to each other.

2. The safety helmet as claimed in claim 1, wherein said sectional parts comprise at least four sections; and wherein said springs bridge the gaps between sectional parts that are adjacent to each other; wherein springs comprise at least three springs.

3. The safety helmet as claimed in claim 1, wherein the plurality of springs and the spring parameters of said springs are modulated to optimize said distribution of force.

4. The safety helmet as claimed in claim 1, wherein the plurality of sectional parts and the arrangement of sectional parts are modulated to optimize said distribution of force.

5. The safety helmet as claimed in claim 1, wherein said gaps between sectional parts that are adjacent to each other are covered by material extending from one sectional part and overlapping the adjacent sectional part.

6. The safety helmet as claimed in claim 1, including end caps affixed to both ends of said springs and anchoring springs immovably to sectional parts that are adjacent to each other.

7. The safety helmet as claimed in claim 1, wherein said springs are anchored immovable at their ends to sectional parts that are adjacent to each other.

8. The safety helmet as claimed in claim 7, wherein adhesive anchors said springs.

9. The safety helmet as claimed in claim 8, wherein said adhesive anchors said springs to radial fasteners penetrating said sectional parts radial to the wearer's head when it is worn.

10. The safety helmet as claimed in claim 8, wherein said adhesive anchors said springs to planar fasteners in plane with the wearer's head when it is worn.

11. The safety helmet as claimed in claim 1, wherein said safety helmet is a sports helmet.

12. A football helmet for distributing outwards and around the helmet an impact force, comprising: at least four sectional parts contoured beside the side, back, and top circumference of the wearer's head when it is worn;wherein said sectional parts that are adjacent to each other are connected by at least three springs;wherein said springs are oriented-planar to the wearer's head when it is worn;wherein said springs are anchored immovable at their ends to sectional parts that are adjacent to each other; andwherein said sectional parts are spaced away from each other by said springs, generating gaps between sectional parts that are adjacent to each other.

13. The football helmet as claimed in claim 12, wherein the plurality of springs and the spring parameters of said springs are modulated to optimize said distribution of force.

14. The football helmet as claimed in claim 12, wherein the plurality of sectional parts and the arrangement of sectional parts are modulated to optimize said distribution of force.

15. The football helmet as claimed in claim 12, wherein said gaps between sectional parts that are adjacent to each other are covered by material extending from one sectional part and overlapping the adjacent sectional part.

16. The football helmet as claimed in claim 12, including end caps affixed to both ends of said springs and affixed to sectional parts that are adjacent to each other.

17. The football helmet as claimed in claim 12, wherein adhesive anchors said springs.

18. The football helmet as claimed in claim 17, wherein said adhesive anchors said springs to radial fasteners penetrating said sectional parts radial to the wearer's head when it is worn.

19. The football helmet as claimed in claim 17, wherein said adhesive anchors said springs to planar fasteners in plane with the wearer's head when it is worn.

20. The football helmet as claimed in claim 12, wherein said sectional parts are spaced away from each other such that impact to one sectional part of said helmet causes spring compression, spring bending radially toward the center of the helmet, and movement of one or more sectional parts toward and away from one another.