HEADGEAR ASSEMBLIES AND HEADGEAR LINERS HAVING FRICTION-REDUCING INTERFACE ELEMENTS

BACKGROUND OF THE INVENTION
Technical Field

Aspects of the present invention relate generally to head protection and the minimization and prevention of head injury. More particularly, aspects of the invention, in their several embodiments, provide helmets, headgear, headgear liners, and helmet assemblies having friction-reducing and/or load-directing interface elements or pads between the headgear liner and the helmet shell.

Description of Related Art

Numerous human activities, such as, recreation and sports, construction, public protection, and armed services expose the human body, especially, the head, to impact and injury. Head injury can be the most traumatic type of bodily injury. Especially when in motion, the exposure of the human head to contact and injury can be a continuous concern, whether the head motion is while in a motorized vehicle or while on a bicycle or walking beneath an active building site. Many attempts have been made in the art of head protection to minimize damage to the skull, brain, and brain stem due to head impact.

Many prior art attempts to address this concern have yielded various helmet designs that provide impact energy absorbing materials, for example, foam rubbers and plastics, in an attempt to provide as much “cushioning” material between the surface of impact and the head. Accordingly, in the state of the helmet art in the early 21st century, it is typical to provide as much foam cushioning within a helmet without detracting from the aesthetic appearance of the helmet. The resulting helmets have been limited in their success in meeting either goal of head protection or aesthetics.

U.S. Pat. No. 8,856,972 of Kirshon first introduced the concept of liquid-filled, fluid-displaced liner technology to the art. This technology was further enhanced as disclosed in U.S. Pat. No. 10,531,699 of Kirshon. This technology is marketed by KIRSH Helmets of Schenectady, New York under the trademarks Fluid Displacement Liner™ technology and FDL™ technology. Though the inventions disclosed in the '972 and the '699 patents provide effective means for dissipating impact loading, further improvements and advantages are provided by aspects of the present inventions.

SUMMARY OF THE INVENTION

Aspects of the present invention provide helmets, headgear, and headgear liners having interface elements or pads that direct loading and/or reduce friction, or enhance slippage, between the headgear liner and the helmet shell to provide enhanced head protection in a broad range of helmet applications and other barrier protection applications. According to some aspects, interrace enhanced head protection in a broad range of helmet and other barrier protection applications.

The present invention employs improved helmets or headgear and headgear liners that accommodate the latest improvements in impact diffusing, fluid-filled headgear liner technology. These headgear and headgear liners include mechanisms, devices, and/or means elements may channel loads on the helmet shell in desired directions to provide for reducing friction between the headgear liner and the internal surface of the headgear to improve headgear and headgear liner performance, for example, under impact loading. Aspects of the invention may also include mechanisms, devices, and/or means to regulate, direct, or channel the transfer of loads, for example, impact loads, from the helmet shell to the fluid-filled liner to enhance the dissipation and absorption of impact forces and energy directed upon the head of the wearer.

Testing of prototype helmet assemblies having liquid-filled headgear liners positioned in helmet shells revealed that friction between the surface of external liner and the internal surface of the helmet shell may affect the impact absorbing capacity of the helmet assembly. Subsequent testing revealed that reducing this friction, or allowing the headgear liner to move or “slip,” for example, locally slip in the vicinity of an impact, while in contact with the internal surface of the helmet shell, may improve the energy absorbing or dissipating capacity of the helmet assembly. Aspects of the present invention include mechanisms and means for reducing friction between the headgear liner and the internal surface of the helmet shell to enhance the protective capacity of a helmet assembly. Testing also revealed that these interface elements can also provide a means to regulate or channel the transfer of loads, for example, impact loads, from the helmet shell to the fluid-filled liner to enhance the dissipation and absorption of impact forces and energy and reduce the forces directed upon the head of the wearer.

Aspects of the present invention include mechanisms and means for reducing friction between the headgear liner and the internal surface of the helmet shell and/or mechanisms and means for reducing the loads transferred to enhance the protective capacity of a helmet assembly.

Aspect of the present invention are not limited for use in helmet technology, but are envisioned to be applicable to any form of protective barrier, for example, body armor or any form of surface protection.

One embodiment of the invention is a helmet or headgear assembly comprising or including: a helmet shell shaped to generally conform to the head of a wearer, the helmet shell having an external surface and an internal surface; a headgear liner, for example, a fluid-filled liner, shaped and adapted to be received by the helmet shell, the head gear liner having an external surface; and at least one interface element positioned between the external surface of the headgear liner and the internal surface of the helmet shell, the at least one interface element providing at least some reduction in friction between the external surface of the headgear liner and the internal surface of the helmet shell.

In one aspect, the at least one interface element may comprise a first surface positioned to face the helmet shell and at least one second surface positioned to face the helmet shell, the at least one second surface distal the first surface. In one aspect, the impact by a load on the helmet shell in a vicinity of the at least one interface element transmits a first portion of the load to the first surface, through the at least one interface element, and into the headgear liner in a first direction, and transmits a second portion of the load to the at least one second surface, through the at least one interface element, and into the headgear liner in a second direction, different from the first direction. In another aspect, the at least one second surface of the at least one interface element comprises a second surface facing the helmet shell at a first distance from the helmet shell and a third surface facing the helmet shell at a second distance, greater than the first distance.

In one aspect, the at least one interface element may be a plurality of interface elements mounted to the internal surface of the helmet shell and/or to the external surface of the headgear liner.

In one aspect, the at least one interface element may be a flexible material mounted to the external surface of the headgear liner by an adhesive, a mechanical fastener, or stitching.

In one aspect, the headgear liner may be a flexible, fluid impermeable enclosure having opposing end walls, a sidewall extending between the opposing end walls, and a fluid contained in the enclosure.

In one aspect, the at least one interface element may be a hook-and-loop-type fastener, for example, a hook-and-loop-type fastener mounted to the external surface of the headgear liner.

In one aspect, the at least one interface element may be two opposing loop sides of hook-and-loop-type fasteners.

In one aspect, the headgear assembly may be a helmet, for example, a baseball catcher's helmet, a baseball batter's helmet, a soft ball catcher's helmet, a softball batter's helmet, a hockey helmet, a hockey goalie mask, a motorcycle helmet, a motor cross helmet, a skiing helmet, a snowboarding helmet, a skateboarding helmet, a lacrosse helmet, a bicycle helmet, a jockey helmet, an official's helmet, a medical protection helmet, a rock or ice climbing helmet, a mountain climbing helmet, a football helmet, a hardhat, or a military helmet.

In one aspect, the headgear may be a “bump cap,” as known in the art. For example, when the situation and/or head clearance discourage the use of a conventional helmet, such as, a hard hat, a smaller and, typically, less obtrusive “bump cap” may be worn to provide the head of the wearer with at least some impact protection, for example, in tight quarters. As known in the art, bump caps may have a shell sized and shaped to conform to the internal shape of helmet shell or to the internal shape of a conventional “baseball cap,” for example, with or without a “visor,” and include some form of internal liner and/or suspension beneath the shell providing head protection not typically provided by conventional helmet shells, baseball caps, or similar headgear. In one aspect of this invention, the interface elements disclosed herein may comprise a bump cap positioned between a helmet shell and a helmet liner, for example, a fluid-filled liner.

In one aspect, the at least one interface element may extend over more than 50% of a surface area of the external surface of the headgear liner. In another aspect, the at least one interface element may extend over more than 80% of the surface area of the external surface of the headgear liner, for example, in one aspect, the at least one interface element may be a “bump cap,” as known in the art.

In one aspect, the at least one interface element may further include a plurality of projections or pins from the internal surface of the at least one interface element, for example, from the internal surface of bump cap, and wherein the headgear liner may include a plurality of recesses or holes, each of the plurality of recesses or holes positioned and adapted to engage one of the plurality of projections or pins. The recesses or holes in the headgear liner may be through holes. In one aspect, the engagement of the plurality of projections or pins with the plurality of recesses or holes at least partially retains the headgear liner within the at least one interface element, for example, a bump cap functioning as an interface element.

Another embodiment of the invention is a headgear liner assembly comprising or including: a headgear liner comprising a flexible, fluid impermeable enclosure having opposing end walls, a sidewall extending between the opposing end walls, and a fluid contained in the enclosure; and at least one interface element mounted to the headgear liner, the at least one interface element providing at least some reduction in friction between the headgear liner and an internal surface of a helmet shell into which the headgear liner is positioned.

In one aspect, the at least one interface element of the headgear liner may comprise a first surface positioned to face a helmet shell and at least one second surface positioned to face the helmet shell, the at least one second surface distal the first surface. In one aspect, the impact by a load on the helmet shell in a vicinity of the at least one interface element transmits a first portion of the load to the first surface, through the at least one interface element, and into the headgear liner in a first direction, and transmits a second portion of the load to the at least one second surface, through the at least one interface element, and into the headgear liner in a second direction, different from the first direction. In another aspect, the at least one second surface of the at least one interface element may comprise a second surface facing the helmet shell at a first distance from the helmet shell and a third surface facing the helmet shell at a second distance, greater than the first distance.

In one aspect, the at least one interface element on the headgear liner may be a hook-and-loop-type fastener mounted to the external surface of the headgear liner. For example, the at least one interface element may be two opposing loop sides of a hook-and-loop-type fasteners.

Another embodiment of the invention is a helmet or a bump cap having the headgear liner described above.

In one aspect, the at least one interface element of the headgear liner assembly may extend over more than 50% of a surface area of an external surface of the headgear liner, or more than more than 80% of the surface area of the external surface of the headgear liner, for example, wherein the at least one interface element may comprise a bump cap.

In another aspect, the at least one interface element of the headgear liner assembly may include a plurality of projections or pins from the internal surface of the at least one interface element, and wherein the headgear liner may include a plurality of recesses or holes, each of the plurality of recesses positioned and adapted to engage one of the plurality of projections or pins. In one aspect, the engagement of the plurality of projections or with the plurality of recesses or holes may at least partially retain the headgear liner within the at least one interface element.

A further embodiment of the invention is a method of protecting the head, the method comprising or including: mounting at least one interface element to an external surface of a headgear liner or an internal surface of a helmet shell, the at least one interface element providing at least some reduction in friction between the external surface of the headgear liner and the internal surface of the helmet shell; inserting the headgear liner into the helmet shell where the at least one interface element is positioned between the external surface of the headgear liner and the internal surface of the helmet shell; and positioning the helmet shell with headgear liner and the at least one interface element onto the head of a user.

In one aspect, the method may further include, upon impact of a load on the helmet shell in the vicinity of the at least one interface element, allowing the helmet shell to move relative to the headgear liner and/or interface element. The relative movement may comprise at least some circumferential or transverse movement between the internal surface of the helmet shell and the external surface of the headgear liner. It is understood that such relative movement can improve the distribution of the impact load to the liner, for example, improve the distribution of the impact load to the fluid of a fluid-filled liner, and thus attenuate or reduce the loading on the head of the wearer.

In another aspect, the interface element may include a first surface positioned to face the helmet shell and at least one second surface positioned to face the helmet shell, the at least one second surface distal the first surface, wherein the method further comprises, upon impact by a load on the helmet shell in a vicinity of the interface element, allowing a first portion of the load to impact the first surface and transmit the first portion of the load through the interface element and into the headgear liner in a first direction, and allowing a second portion of the load to impact the at least one second surface and transit the second portion of the load through the interface element and into the headgear liner in a second direction, different from the first direction. In one aspect, the at least one second surface may comprise the second surface and a third surface, wherein the method further comprises allowing a third portion of the load to impact the third surface and transmit the third portion of the load through the interface element and into the headgear liner in a third direction, different from the first direction and the second direction. According to one aspect of the invention, the first, the second, and/or the third directions may be generally transverse or substantially parallel to the external surface of the headgear liner. However, it is believed that at least a component of the first, the second, and/or the third direction may also be directed radially, for example, a component of the first, the second, and/or the third direction may be directed substantially perpendicular to the external surface of the headgear liner.

In one aspect, the method may further comprise, upon impact by a load on the helmet shell in a vicinity of the at least one interface element, reducing transmission of the load to the head of the user compared to a load transmitted to the head when no interface element is provided.

A further embodiment of the invention is a method for dispersing loading upon a barrier to a fluid-containing liner, the method comprising or including: positioning an interface element between a barrier (for example, a helmet shell, a body armor panel, or a stadium wall) and a fluid-containing liner, the interface element having a first surface facing the barrier and at least one second surface facing the barrier, the at least one second surface distal the first surface; allowing the barrier to be impacted by a load in the vicinity of the interface element; transmitting a first portion of the load upon the barrier to the first surface and through the interface element to the fluid-containing liner in a first direction; and, after transmitting the first portion to the first surface, transmitting a second portion of the load to the at least one second surface of the interface element and through the interface element to the fluid-containing liner in a second direction, different from the first direction.

In one aspect, the at least one second surface of the interface element may comprise a second surface facing the barrier at a first distance from the barrier and a third surface facing the barrier at a second distance greater than the first distance.

In another aspect, the fluid-containing liner may comprise a flexible, hollow liner encasing a fluid. In one aspect, at least one of the first direction and the second direction comprises a direction substantially parallel to a plane of the first surface. As noted herein, according to one aspect of the invention, at least a component of the first, the second, and/or the third direction may also be directed radially, for example, substantially perpendicular to the external surface of the interface element.

In another aspect, the method further comprises allowing the interface element and/or fluid-containing liner to at least partially move relative to the barrier, for example, by reducing the friction due to the at least partial movement of the interface element relative to the barrier.

In one aspect, the step of positioning the interface element between the barrier and the fluid-containing liner may comprise positioning a plurality of interface elements, that is, more than one, where each of the plurality of interface elements has a first surface facing the barrier and at least one second surface facing the barrier, the at least one second surface distal the first surface. For example, in one aspect, positioning the plurality of interface elements comprises positioning a plurality of interface elements wherein each of the plurality comprises a first surface directed in a first direction from the other first surfaces of the other interface elements of the plurality of interface elements.

Another embodiment of the invention is a device for dispersing loading on a barrier (for example, a helmet shell or body armor panel) upon a fluid-containing liner, the device comprising or including: an interface element adapted to be positioned between a barrier and a fluid-containing liner, the interface element having a first surface positioned to face the barrier and at least one second surface positioned to face the barrier, the at least one second surface distal the first surface; wherein, when positioned between the barrier and the fluid-containing liner, impact by a load on the barrier in a vicinity of the interface element transmits a portion of the load to the first surface, through the interface element, and into the fluid-containing liner in a first direction, and then transmits a second portion of the load to the at least one second surface, through the interface element, and into the fluid-containing liner in a second direction, different from the first direction.

In one aspect, the barrier may be a protective panel, such as, a helmet shell, a knee pad, a shoulder pad, a shin pad, or any other bodily protection or body armor, an athletic barrier (such as, a stadium wall or stanchion), military body armor or police body armor, among other protective apparel.

In one aspect, the fluid-containing liner may comprise a flexible hollow liner encasing a fluid, for example, an oil, or an alcohol.

In one aspect, the device may comprise a friction-reducing material, for example, a polytetrafluoroethylene (PTFE) material.

In one aspect, the device may further comprise a base element having guide members, wherein a first of the guide members comprises the first surface and a second of the guide members comprises the second surface. In one aspect, the guide members may comprise projections from the base element.

In one aspect, the interface element may comprise a plurality of pieces of hook-and-loop type fasteners.

These and other aspects, features, and advantages of this invention will become apparent from the following detailed descriptions of the various aspects of the invention taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention will be readily understood from the following detailed description of aspects of the invention taken in conjunction with the accompanying drawings in which:

FIG. 1 is a top perspective view of a helmet or headgear assembly according to one aspect of the invention.

FIG. 2 is an exploded perspective view of the helmet or headgear assembly shown in FIG. 1.

FIG. 3 is an exploded perspective view of the headgear liner assembly shown in FIG. 2.

FIG. 4 is a plan view of one interface element shown in FIG. 3 according to one aspect of the invention.

FIG. 5 is a side elevation view of the interface element shown in FIG. 4.

FIG. 6 is a top perspective view of a helmet or headgear assembly according to another aspect of the invention.

FIG. 7 is an exploded perspective view of the helmet or headgear assembly shown in FIG. 6.

FIG. 8 is a top plan view of a liner assembly that may be used for the liner assembly shown in FIGS. 6 and 7.

FIG. 9 is a top plan view of another liner assembly that may be used for the liner assembly shown in FIGS. 6 and 7.

FIG. 10 is a front perspective view of the liner assembly shown in FIG. 9.

FIG. 11 is a top plan view of one interface element shown in FIGS. 8 and 9 according to one aspect of the invention.

FIG. 12 is a side elevation view of the interface element shown in FIG. 11 as viewed along view lines 12-12 in FIG. 11.

FIG. 13 is a side elevation view of the interface element shown in FIG. 11 as viewed along view lines 13-13 in FIG. 11.

FIG. 14 is an exploded perspective view of the interface element shown in FIG. 11.

FIG. 15 is a plan view of a portion of the headgear liner assembly identified by Detail 15 shown in FIGS. 8 or 9.

FIG. 16 is a cross-sectional view of the portion of the headgear liner assembly shown in FIG. 15 as viewed along view lines 16-16 in FIG. 15.

FIG. 17 is another plan view of the portion of the headgear the liner assembly shown by Detail 15 shown in FIGS. 8 or 9.

FIG. 18 is a cross-sectional view of the portion of the headgear liner assembly shown in FIG. 17 as viewed along section lines 18-18 in FIG. 17.

FIG. 19 is a top plan view of another interface element shown in FIGS. 8 and 9 according to an aspect of the invention.

FIG. 20 is a side elevation view of the interface element shown in FIG. 19 as viewed along view lines 20-20 shown in FIG. 19.

FIG. 21 is a side elevation view of the interface element shown in FIG. 19 as viewed along view lines 21-21 shown in FIG. 19.

FIG. 22 is a top plan view of another interface element shown in FIGS. 8 and 9 according to an aspect of the invention.

FIG. 23 is a side elevation view of the interface element shown in FIG. 22 as viewed along view lines 23-23 shown in FIG. 22.

FIG. 24 is a side elevation view of the interface element shown in FIG. 22 as viewed along view lines 24-24 shown in FIG. 22.

FIG. 25 is a perspective view of a helmet assembly according to a further aspect of the invention.

FIG. 26 is an exploded perspective view of the helmet assembly shown in FIG. 25.

FIG. 27 is a plan view of the fluid-filled helmet liner shown in FIG. 26.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is a top perspective view of a helmet or headgear assembly 10 according to one aspect of the invention. FIG. 2 is an exploded perspective view of the helmet or headgear assembly 10 shown in FIG. 1. In the following disclosure of the invention, though assembly 10 and its components may be referred to as a “helmet assembly,” a “helmet shell,” or a “helmet,” it is envisioned and understood that assembly 10 may comprise any form of “headgear,” that is, not specifically a protective helmet. For example, aspects of the invention may be applicable to any form of headwear, protective or otherwise, including pump caps, as disclosed herein. It is also envisioned that aspects of the invention may be applicable to any form of protective barrier, for example, body armor or any form of surface protection.

As shown in FIGS. 1 and 2, in one aspect, headgear assembly 10 includes a helmet shell 12 and a helmet or headgear liner assembly 14. According to one aspect of the invention, headgear liner assembly 14 may comprise a headgear liner 16, for example, a fluid-filled headgear liner as disclosed in U.S. Pat. No. 8,856,972 and U.S. Pat. No. 10,531,699, or in pending U.S. application Ser. No. 16/595,135 filed on Oct. 7, 2019; pending U.S. application Ser. No. 16/738,234, filed on Jan. 9, 2020; pending U.S. application Ser. No. 17/020,888, filed on Sep. 15, 2020; and pending U.S. application Ser. No. 17/015,738, filed on Sep. 9, 2020, the disclosures of which are incorporated by reference herein in their entirety. These and related helmet or headgear liners are marketed under the trademark Fluid Displacement Liner™ technology by Kirsh Helmets. In other aspects, headgear liner 16 may be any headgear or helmet liner adapted to be received by a helmet shell, such as, helmet shell 12. Helmet shell 12 includes an internal surface 18 and an external surface 19, and liner 16 includes an external surface 20.

In order to facilitate disclosure of the invention, in FIGS. 1 and 2, helmet shell 12 is shown transparent to allow illustration of the liner assembly 14 and its components positioned within helmet shell 12. However, as is typical in the art, helmet shell 12 may be opaque, and be tinted, for example, with an aesthetically appealing color or design, though shell 12 may be transparent or translucent. Helmet shell 12 may typically be made of plastic, for example, a polycarbonate, such as, a polycarbonate shell fabricated by injection molding, or an equivalent process. In one aspect, helmet shell 12 may comprise one of the helmets or helmet shells shown in U.S. Design Pat. Nos. 844,252; 853,038; 877,986; and 869,778, which are included by reference herein.

According to aspects of the invention, helmet assembly 10 includes some form of mechanism, device, or means for reducing the friction between helmet shell 12 and headgear liner 16. Specifically, aspects of the invention include some form of mechanism, device, or means for reducing the friction between internal surface 18 of helmet shell 12 and the external surface 20 of headgear liner 16. In one aspect, the device for reducing the friction may comprise any interface, interfaces, structure, or structures positioned between internal surface 18 of helmet shell 12 and the external surface 20 of headgear liner 16. In one aspect, the friction-reducing interface, interfaces, structure, or structures may extend over at least a portion of internal surface 18 and/or over at least a portion of external surface 20. In another aspect, the friction-reducing interface, interfaces, structure, or structures may extend over a substantial portion (for example, more than 50% of the surface area) of internal surface 18 and/or over a substantial portion of external surface 20. In another aspect, the friction-reducing interface, interfaces, structure, or structures may extend substantially completely over (for example, more than 80% of the surface area) internal surface 18 and/or substantially completely over external surface 20. See FIGS. 25 and 26 for an example of an interface element extending substantially completely over the external surface of a fluid-filled liner. In one aspect, the interface, interfaces, structure, or structures between internal surface 18 of helmet shell 12 and the external surface 20 of headgear liner 16 may comprise a material characterized by providing reduced friction, for example, a polytetrafluoroethylene (PTFE), such as, a DuPont Teflon® PTFE, or its equivalent, or a Saint-Gobain Rulon® PTFE, or its equivalent.

In is envisioned that aspects of the invention may provide at least 5% reduction in friction, for example, at least a 5% reduction in the coefficient of friction (static or dynamic) between internal surface 18 of helmet shell 12 and the external surface 20 of headgear liner 16. However, it is envisioned that aspects of the invention may provide at least a 10% reduction in coefficient of friction, or at least a 20% reduction in the coefficient of friction between internal surface 18 of helmet shell 12 and the external surface 20 of headgear liner 16.

In one aspect of the invention, the reduction in the coefficient of friction may be provided by a fluid, for example, an oil-based lubricant or the like. In another aspect of the invention, the reduction in the coefficient of friction may be provided by a solid, for example, a graphite powder or the like.

In one aspect, the internal surface 18 of helmet shell 12, the external surface 20 of headgear liner 16, or both may be treated, for example, chemically or mechanically, to enhance the reduction in friction between the mating surfaces. For example, the internal surface 18 of helmet shell 12, the external surface 20 of headgear liner 16, or both may be sanded or polished to provide reduced friction. In another aspect, the internal surface 18 of helmet shell 12, the external surface 20 of headgear liner 16, or both may be coated with the friction reducing compound, such as, a PTFE-containing compound, or the like.

In one aspect of the invention, as shown in FIG. 2, at least one, but typically a plurality of interface elements or “pads” 22 may be provided to surface 20 to provide at least some reduction in friction between internal surface 18 of helmet shell 12 and the external surface 20 of headgear liner 16. FIG. 3 is an exploded perspective view of the headgear liner assembly 14 shown in FIG. 2 with interface elements or pads 22 isolated from the liner 16. As shown in FIGS. 2 and 3, headgear liner 16, for example, a fluid-filled headgear liner may have a plurality of through holes 24. Headgear liner 16 may also have a plurality of radial slots 26 allowing the liner 16 to conform to, for example, manipulated and positioned into, the internal shape of helmet shell 12.

As shown in FIG. 2, in one aspect, interface elements or pads 22 may be positioned on surface 20 of headgear liner 16 where the pads 22 at least partially cover or bridge a radial slot 26 in liner 16. In one aspect, pads 22 may be mounted or fixed, for example, with an adhesive, to one side of a radial slot 26 in liner 16 while not being fixed or mounted to the other side of radial slot 26. For example, in one aspect, a pad 22 may be mounted to a surface on one side of a radial slot 26 while also being allowed to “float” or slide with little or no restriction on the surface of the opposite other side of slot 26. It is envisioned that allowing at least a portion of pad 22 to float, permits the pad 22 to be minimally affected by any separation or relative movement of the surfaces adjacent slot 26 and without deflecting, stretching, or stressing pad 22. In one aspect of the invention, pads 22 may be fabricated from an elastic material, for example, one or more of the rubbers or elastomers disclosed herein, and thus accommodate any relative movement of surfaces adjacent slots 26.

The interface elements or pads 22 may be mounted to the internal surface 18 of helmet shell 12, to the external surface 20 of headgear liner 16, or to both surfaces. Pads 22 may be mounted to the internal surface 18 of helmet shell 12 or the external surface 20 headgear liner 16 with an adhesive, one or more mechanical fasteners, stitching, or thermal fusion (for example, welding), and the like. In one aspect, interface elements or pads 22 may not be fixed to either surface 18 or surface 16 but be allowed to “float” between surfaces while providing the desired reduction in friction.

Interface elements or pads 22 may comprise a broad range of materials and material surface textures. For example, in one aspect, pads 22 may comprise a plastic, for example, a polyamide (PA), for example, nylon; a polyethylene (PE), both high-density polyethylene (HDPE) and low-density polyethylene (LDPE); a polyethylene terephthalate (PET); a polypropylene (PP); a polyester (PE); a polytetrafluoroethylene (PTFE); a polystyrene (PS); an acrylonitrile butadiene styrene (ABS); a polycarbonate (PC); or a polyvinylchloride (PVC); among other plastics. In another aspect, pads 22 may comprise an elastic material, such as, a rubber or an elastomer, for example, a natural polymer, such as, polyisoprene rubber, or a synthetic polymer, such as, a neoprene, a thermoplastic elastomer, a thermoplastic rubber, and a polyvinyl chloride, or an ethylene propylene diene monomer (EPDM) rubber, and the like. In another aspect, pads 22 may comprise a wood (for example, in the form of paper) or a metal while providing the desired reduction in friction.

In one aspect, pads 22 may provide a substantially smooth surface against the mating or opposing surface. In another aspect, pads 22 may provide an irregular surface, for example, one with projections, undulations, asperities, or “hills and valleys,” for instance, providing isolated points or regions of contact with the mating or opposing surface.

In the aspect of the invention shown in FIG. 3, interface elements or pads 22 may be flexible or pliant, for example, readily conforming to the shape and texture of the internal surface 18 of helmet shell 12 and/or the external surface 20 of headgear liner 16. In one aspect, pads 22 may comprise a woven or unwoven fabric, for example, a natural fabric such as, cotton or wool, or a synthetic fabric, for example, fabricated from threads of any one or more of the plastics or polymers disclosed herein.

In one aspect, pads 22 may be fabricated from hook-and-loop-type fastener materials, for example, a Velcro® hook-and-loop-type fastener material. In one aspect, the hook-and-loop-type fastener material may be mounted to internal surface 18 of helmet shell 12 and/or to external surface 20 of headgear liner 16 wherein either the “loop-side” or the “hook side” of the hook-and-loop-type material may bear against the opposing surface. For example, in one aspect, pads 22 may comprise hook-and-loop-type fastener material where the pad 22 may be mounted to the external surface 20 of headgear liner 16 where either the loop side or the hook side may bear against the opposing internal surface 18 of the helmet shell 12. In one aspect, pads 22 may be mounted to the external surface 20 of headgear liner 16 where the hook side of the hook-and-loop-type fastener may bear against the opposing internal surface 18 of the helmet shell 12. In one aspect, pads 22 may comprise a hook-and-loop-type fastener material comprising opposing “hook side” and “loop side,” where one side provides a mounting to the surface 18 or surface 20 (via a corresponding hook-and-loop-type fastener mounted to surface 18 or surface 20) and the opposing side provides the friction-reducing bearing surface against surface 18 or surface 20, as appropriate. Alternative arrangements of the mounting of “loop-side” or the “hook side” of a hook-and-loop-type material to internal surface 18 and/or to external surface 20 may be apparent to those of skill in the art.

FIG. 4 is a plan view of one interface element 22 shown in FIG. 3 according to one aspect of the invention and FIG. 5 is a side elevation view of the interface element 22 shown in FIG. 4. In one aspect of the invention, interface element or pad 22 may assume a broad range of geometric shapes while providing the desired reduction in friction. These shapes include circular, rectangular, square, elliptical, or any conventional polygonal shape.

In the aspect of the invention shown in FIGS. 4 and 5, pad 22 is shown in a general rounded rectangular shape or “race track oval” type shape. As shown in FIG. 4, pad 22 may have a dimension 28, that is, a length, a width, or a diameter, ranging from 0.25 inches to 12 inches, depending, among other things, upon the size of liner 16, but typically has a dimension 28 ranging between 1 inch and 3 inches.

As shown in FIG. 5, pad 22 may typically have rounded ends, though in other aspects, the ends may not be rounded, and a thickness 30. The thickness 30 of pad 22 may range from 0.0625 inches to 2 inches, depending, among other things, upon the size of liner 16, but typically thickness 30 ranges between 0.125 inches and 0.5 inches.

In one aspect of the invention, as shown in FIG. 5, pad 22 may comprise two components 32 and 34 mated along an interface 36 (shown by a dashed line). Components 32 and 34 may be substantially the same materiel or different materials. In one aspect, interface 36 may comprise an adhesive mating the components 32 and 34.

In one aspect, components 32 and 34 may each comprise a hook-and-loop-type fastener material, for example, the same or a different hook-and-loop-type fastener material. For instance, in one aspect, components 32 and 34 may comprise a “hook side,” a “loop side,” or both of a hook-and-loop-type faster material, wherein the interface 36 comprises the backing adhesive that may typically be provided with hook-and-loop-type fasteners. In one aspect, interface elements or pads 22 may comprise components 32 and 34 each having a “hook side” surface of the hook-and-loop-type fastener while mated along interface 36 thus exposing the “hook side” surface on either side of pads 22 for bearing against and reducing friction with a mating surface. In one aspect, the dual component pad 22 shown in FIG. 5 may be mounted to surface 18 and/or surface 20 with an adhesive, a mechanical fastener, and/or a corresponding hook-and-loop-type faster mounted to surface 18 and/or surface 20.

The hook-and-loop-type fasteners used for pad 22 may comprise a plastic hook-and-loop-type fastener, for example, a nylon hook-and-loop-type fastener, or a hook-and-loop type fastener made of any one of the plastics disclosed herein. In one aspect, the hook-and-loop type fastener used for pad 22 may be a Velcro® brand hook-and-loop-type fastener provided by Velcro, USA, for example, a nylon loop Velcro® hook-and-loop-type fastener having model number 158505, or its equivalent.

FIG. 6 is a top perspective view of a helmet or headgear assembly 50 according to another aspect of the invention. FIG. 7 is an exploded perspective view of the helmet or headgear assembly 50 shown in FIG. 6. As discussed with respect to headgear assembly 10, in the following disclosure of this aspect of the invention and throughout this disclosure, though assembly 50 and its components may be referred to as a “helmet assembly,” a “helmet shell,” or a “helmet,” it is envisioned and understood that assembly 50 may comprise any form of “headgear,” that is, not specifically a protective helmet. For example, aspects of the invention may be applicable to any form of headwear, protective or otherwise, including pump caps, as disclosed herein. It is also envisioned that aspects of the invention may be applicable to any form of protective barrier, for example, body armor or any form of surface protection.

As shown in FIGS. 6 and 7, in one aspect, headgear assembly 50 includes a helmet shell 52 and a helmet or headgear liner assembly 54 positioned within shell 52. According to one aspect of the invention, headgear liner assembly 54 may comprise a headgear liner 56, for example, a fluid-filled headgear liner as disclosed in any one of the cited US patents or pending US applications incorporated by reference herein. In other aspects, headgear liner 54 may be any headgear or helmet liner adapted to be received by a helmet shell, such as, helmet shell 52. Helmet shell 52 includes an internal surface 58 and an external surface 59, and liner 56 includes an external surface 60.

As shown in FIGS. 6 and 7, headgear liner 56 may have a plurality of through holes 64 and headgear liner 56 may also have a plurality of radial slots 66 allowing the liner 56 to conform to, for example, be manipulated and positioned into, the internal shape of helmet shell 52.

In order to facilitate disclosure of the invention, in FIGS. 6 and 7, helmet shell 52 is shown transparent to allow illustration of the liner assembly 54 and its components positioned within helmet shell 52. However, as is typical in the art, helmet shell 52 may typically be opaque, and be tinted, for example, with an aesthetically appealing color or design, though shell 52 may be transparent or translucent. Helmet shell 52 may typically be made of plastic, for example, a polycarbonate, such as, a polycarbonate shell fabricated by injection molding, or an equivalent process. In one aspect, helmet shell 52 may comprise one of the helmets or helmet shells disclosed in U.S. Design Pat. Nos. 844,252; 853,038; 877,986; and 869,778, which are included by reference herein.

According to aspects of the invention, helmet assembly 50 includes some form of mechanism, device, or means for reducing the friction between helmet shell 52 and headgear liner 56 and/or some form of mechanism, device, or means for directing the transmission of loading upon the helmet shell 52 to the headgear liner 56 to enhance energy absorption and minimize the loading directed to the head of the wearer, not shown. Specifically, though in some aspects of the invention some form of mechanism, device, or means may be provided for reducing the friction between internal surface 58 of helmet shell 52 and the external surface 70 of headgear liner 56, for example, as disclosed in pending application Ser. No. 17/020,888, aspects of the present invention provide an interface, interfaces, structure, or structures positioned between internal surface 58 of helmet shell 52, or any helmet shell disclosed herein, and the external surface 70 of headgear liner 56, or of any headgear liner disclosed herein, adapted to direct or “channel” any loading on the helmet shell 52 in a preferred direction upon the headgear liner 56 to enhance the absorption of energy by the headgear liner 56 and/or by the helmet assembly 50.

In one aspect, the load channeling provided by the interface, interfaces, structure, or structures may extend over at least a portion of internal surface 58 and/or over at least a portion of external surface 60. In another aspect, the load channeling interface, interfaces, structure, or structures may extend over a substantial portion (for example, more than 50% of the surface area) of internal surface 58 and/or over a substantial portion of external surface 70. In another aspect, the friction-reducing and/or the load-directing interface, interfaces, structure, or structures may extend substantially completely over (for example, more than 80% of the surface area of) internal surface 58 and/or substantially completely over external surface 60. In one aspect, the interface, interfaces, structure, or structures between internal surface 58 of helmet shell 52 and the external surface 60 of headgear liner 56 may comprise a material characterized by providing reduced friction, for example, a polytetrafluoroethylene (PTFE), such as, a DuPont Teflon® PTFE, or its equivalent, or a Saint-Gobain Rulon® PTFE, or its equivalent.

In is envisioned that aspects of the invention may provide at least 5% reduction in friction, for example, at least a 5% reduction in the coefficient of friction (static or dynamic) between internal surface 58 of helmet shell 52 and the external surface 60 of headgear liner 56. However, it is envisioned that aspects of the invention may provide at least a 10% reduction in coefficient of friction, or at least a 20% reduction in the coefficient of friction between internal surface 58 of helmet shell 52 and the external surface 60 of headgear liner 56.

In one aspect of the invention, as shown in FIG. 7, at least one, but typically a plurality of interface elements or “pads” 62 may be provided to provide at least some reduction in friction between internal surface 58 of helmet shell 52 and the external surface 60 of headgear liner 56 and/or to provide at least some channeling or directing of loading in a preferred direction upon the headgear liner 56 to enhance the absorption of energy by the liner 56 and/or helmet assembly 50.

FIG. 8 is a top plan view of a liner assembly 74 that may be used for liner assembly 54 shown in FIGS. 6 and 7. FIG. 9 is a top plan view of a liner assembly 75 that may be used for liner assembly 54 shown in FIGS. 6 and 7. FIG. 10 is a front perspective view of the liner assembly 75 shown in FIG. 9. As shown in FIGS. 8, 9, and 10, liner assembly 74 or 75 may comprise a headgear liner 76, for example, a fluid-filled headgear liner as disclosed in U.S. Pat. Nos. 8,856,972 and 10,531,699, and a plurality of interface elements 78, 80, 82, and 84, for example, similar to interface element 62 shown in FIGS. 6 and 7. As shown in FIGS. 8, 9, and 10, in one aspect, and similar to headgear liner 56, headgear liner 76 may have a plurality of through holes 86 and may also have a plurality of radial slots 88 allowing the liner 76 to conform to, for example, be manipulated and positioned into, the internal shape of a helmet shell, such as, helmet shell 52. In one aspect, headgear liner 76 may include a plurality of mounting pads 90, for example, hook-and-loop type pads, adapted to engage complementary pads mounted on the inner surface 58 of the helmet shell 52.

According to aspects of the invention interface elements 78, 80, 82, and 84 are designed to modify, regulate, or channel the loads received by the helmet shell 52 into which liner assembly 74 or 74 is positioned to enhance the performance of the helmet/liner assembly, for example, to reduce the loading transferred from the helmet shell to the head of the wearer. In one aspect, this modification, regulation, and/or channeling of loads is effected by providing surfaces of varying height or thickness on interface elements 78, 80, 82, and 84 whereby surfaces of greater height or thickness receive and direct loadings in desired, predetermined direction(s) upon the headgear liner 76.

Interface elements 78, 80, 82, and 84 may be mounted to headgear liner 76 of liner assembly 74 or 75 by conventional means, for example, with fasteners, such as, hook-and-loop type fasteners, an adhesive, or molded or otherwise formed into liner 76.

FIG. 11 is top plan view of one interface element 78 shown in FIGS. 8, 9, and 10 according to one aspect of the invention. FIG. 12 is a side elevation view of interface element 78 shown in FIG. 11 as viewed along view lines 12-12 in FIG. 11; and FIG. 13 is a side elevation view of interface element 78 shown in FIG. 11 as viewed along view lines 13-13 in FIG. 11. FIG. 14 is an exploded perspective view of interface element 78 shown in FIG. 11.

Though interface element 78 (and any interface element disclosed herein) may be formed from a broad range of fabrication processes, for example, machining, stamping, 3-D printing, molding, laser cutting, and the like, in the aspect of the invention shown in FIGS. 11 through 14, interface element 78 is fabricated by multiple components to facilitate development, fabrication and/or evaluation. In the aspect shown, the multiple components shown may be assembled by conventional means, for example, with fasteners, adhesives, welding, or soldering, and the like. According to one aspect, the components of interface element 78 may be fabricated with hook-and-loop type fasteners, for example, Velcro® brand hook-and-loop fasteners. In one aspect, the individual components of interface element 78 shown in FIGS. 11 though 14 may be fabricated by cutting the components from hook-and-loop type fastener material, for example, from sheets or strips of hook-and-loop type fastener materials.

As shown in FIGS. 11 through 14, in one aspect, interface element 78 (and any interface element disclosed herein) may include a base element 92 and a plurality of guide elements 94, 96, 98, 100, 102, and 104 mounted to base element 92. Though base element 92 and guide elements 94, 96, 98, 100, 102, and 104 are shown generally polygonal in shape with one or more rounded edges, the shapes of base element 92 and guide elements 94, 96, 98, 100, 102, and 104 may vary broadly while still providing the desired function. In one aspect, guide elements 94, 96, 98, 100, 102, and 104 may comprise projections from base element 92, for example, projections formed in or upon base element 92.

As shown most clearly in FIG. 14, guide element 94 may be mounted to base element 92 and guide element 100 may be mounted to guide element 94 to provide first and second contact surface A on guide element 100 and contact surface B on guide element 94 as shown in FIG. 11. According to aspects of the invention, contact surface A on guide element 100 may be “higher than” or distal contact surface B where, upon impact of the adjacent helmet shell, contact surface A contacts and receives loading prior to contact surface B. According to aspects of the invention, this prior contact and loading, no matter how small the difference in contact time, promotes the reception and transmission of a load upon contact surface A on guide element 100 before the reception and transmission of the load to contact surface B on guide element 94. It is believed that prior contact and loading on contact surface A promotes the transmission of load to the adjacent liner, for example, to a fluid-containing liner, at a preferred time and in a desired, previously defined direction to enhance the energy absorbing capacity of the liner or helmet/liner combination. In one aspect, interface element 78 may only include only guide elements 94 and 100 on base element 92 to provide contact surfaces A and B only.

Similarly, in one aspect, as shown most clearly in FIG. 14, guide elements 96 and 98 may be mounted to base element 92 and guide elements 102 and 104 may be mounted to guide elements 96 and 98, respectively, to provide third contact surface C on guide element 102 and fourth contact surface D on guide element 104 as shown in FIG. 11. Again, according to an aspect of the invention, contact surface C on guide element 102 and contact surface D on guide element 104 may be “higher than” or distal contact surface B on guide element 94 where, upon impact of the adjacent helmet shell, contact surfaces C and D (depending upon the angle of impact) contact and receive loading prior to contact surface B. In the aspect of the invention shown in FIGS. 11 through 14, contact surfaces C and D are shown located at about the same elevation of contact surface, wherein contact with surfaces A, C, and D may occur substantially simultaneously and induce substantially simultaneous fluid flows in the liner in the directions shown. However, in other aspects of the invention, at least one of contact surfaces C and D (that is, either contact surface C or contact surface D or both) may be higher than contact surface B, but lower than contact surface A, where, for example, the sequence of reception and transmission may comprise the sequence: surface A, then surface C and/or D, and then surface B. Again, according to aspects of the invention, this prior contact, reception, and/or loading, no matter how small the difference in contact time, promotes the reception and transmission of a load upon contact surfaces on interface element 78 that may be used to promote the transmission of load to the adjacent liner at a preferred time and in a desired, previously defined direction to enhance the energy absorbing capacity of the liner or helmet/liner combination. In one aspect, interface element 78 may only include guide elements 96 and 102 and/or guide elements 98 and 104 on base element 92 to provide contact surfaces C and/or D only.

FIGS. 15 through 18 schematically illustrate the perceived effect of aspects of the invention on the reception and transmission of load to the liner 76 by interface element 78 shown in FIGS. 11 through 14 according to one aspect of the invention. FIG. 15 is a plan view of a portion of headgear liner assembly 74 or 75 having headgear liner 76 about interface element 78 as indicated by Detail 15 shown in FIGS. 8 and 9. FIG. 15 also includes the respective contact surfaces A, B, C, and D disclosed and discussed with respect to FIGS. 11 through 14. FIG. 16 is a cross-sectional view of the portion of headgear liner assembly 74 or 75 shown in FIG. 15 as viewed along view lines 16-16 shown in FIG. 15. According to one aspect, liner 76 of liner assembly 74 or 75 may typically contain a fluid 77, such as, an oil or an alcohol.

In the aspect of the invention shown in FIGS. 15 and 16, for the sake of illustration, contact surfaces C and D are positioned at an elevation substantially the same as the elevation of contact surface A, but higher than contact surface B. In this aspect, the sequential reception and transition of load from a helmet shell upon the contact surfaces of interface element 78 may comprise the sequence: surfaces A, C, and D substantially simultaneously, and then surface B. In one aspect of the invention, load may or may not be received and transmitted through contact with the helmet shell (not shown) with the surface of base element 92 of interface element 78.

As illustrated in FIGS. 15 and 16, and as described with respect to FIGS. 11 through 14, with the positioning and relative elevations of surfaces A, B, C, and D, for example, on interface element 78, the sequential impact of surfaces A, B, C, and, D on interface element 78 can be used to control, regulate, and/or channel the transmission of force from a helmet shell (not shown) to fluid 77 within headgear liner 76. For example, as shown in FIG. 16, initial contact with or reception by the most elevated or highest contact surface A by the force indicated by arrow 110 in FIG. 16, interface element 78 can transmit the force no through interface element 78 to headgear liner 76 and to fluid 77. It is envisioned that this localized loading or compression of liner 76, which may typically be flexible, can compress fluid 77 and promote a fluid flow in fluid 77 as indicated schematically by arrow 112 (that is, in this example, in a direction out of the page of FIG. 16). According to aspects of the invention, this directed and sequential control and/or channeling of flow of the fluid 77 within headgear liner 76 by reception of load on contact surface A (or any other contact surface disclosed herein) enhances the absorption and/or dissipation of the force 110 by liner 76 to reduce the force transmitted to the head of the wearer.

FIG. 17 is a plan view of a portion of headgear liner assembly 74 or 75 having headgear liner 76 about interface element 78 shown in FIGS. 15 and 16 upon contact of surfaces C and D, for example, subsequent to the reception of force no on surface A or at substantially the same time as reception of force no on surface A. FIG. 18 is a cross-sectional view of the portion of headgear liner assembly 74 or 75 as viewed along view lines 18-18 shown in FIG. 17, similar to the cross section shown in FIG. 16. In a fashion similar to that shown in FIGS. 15 and 16, in the aspect of the invention shown in FIGS. 17 and 18, contact surfaces C and D are positioned at an elevation about the same as contact surface A, though in one aspect, contact surfaces C and D may be both lower or both higher than the elevation contact surface A, but higher than contact surface B. In one aspect, the elevations of contact surfaces C and D of interface element 78 may also be different.

As illustrated in FIGS. 17 and 18, and as described with respect to FIGS. 11 through 14, with the positioning and relative elevations of surfaces A, B, C, and D, the impact of loads on surfaces C and D substantially simultaneous with or after reception and transition of force no on contact surface A, the reception of forces upon surfaces C and D may be indicated by arrows 114 and 116, respectively, in FIG. 18. Again, according to an aspect of the invention, the reception and transmission of forces 114 and 116 on contact surfaces C and D, respectively, can transmit force through interface element 78 to headgear liner 76 to promote a fluid flow in fluid 77 as indicated schematically by arrows 118 and 120 (that is, in a direction out of the page of FIG. 18), for example, in a direction substantially parallel to the plane of the first contact surface A. According to aspects of the invention, this sequential and directed flow control and/or channeling of flow of the fluid 77 within headgear liner 76 can enhance the absorption and/or dissipation of the forces 114 and 116 by liner 76 to reduce the force transmitted to the head of the wearer. In addition, in one aspect, the simultaneous or subsequent reception of load by surface B of interface element 76 may promote a fluid flow and energy dissipation and/or absorption in fluid 77 as indicated schematically by arrow 122 shown in FIG. 17.

It is to be understood that the directions of flow illustrated by arrows 112, 118,120, and 122 in FIGS. 15 through 18 are examples only to facilitate disclosure of aspects of the invention. It is envisioned that these directions of fluid flow may vary depending, among other things, upon the presence of adjacent structures within the fluid-filled liner 76 (for example, a liner sidewall or a through-hole sidewall) and the direction of impact of the load upon the helmet shell. For example, it is envisioned that in some aspects of the invention the direction of fluid flow induced within the fluid-filled liner 76 may be different from the directions indicated by arrows 112, 118, 120, and 122. For instance, it is envisioned that the flows may be in an opposite direction to the direction of arrows 112, 118, 120, and 122, for example, as indicated by arrows 124 and 126 in FIGS. 15 and 17. In addition, it is envisioned that the direction of fluid flow induced within the fluid-filled liner 76 may be in a non-orthogonal direction or in an oblique direction, that is, in any direction not represented by arrows 112, 118, 120, 122, 124, and 126.

FIG. 19 is top, plan view of another interface element 82 shown in FIGS. 8 and 9 according to an aspect of the invention. FIG. 20 is a side elevation view of interface element 82 shown in FIG. 19 as viewed along view lines 20-20 shown in FIG. 19; and FIG. 21 is a side elevation view of interface element 82 shown in FIG. 19 as viewed along view lines 21-21 shown in FIG. 19.

As descried with respect to interface element 78, interface element 82 may be formed from a broad range of fabrication processes, for example, machining, stamping, 3-D printing, molding, laser cutting, and the like. In the aspect of the invention shown in FIGS. 19 through 21, interface element 82 is fabricated by multiple components to facilitate development, fabrication, and/or evaluation. In the aspect shown, the multiple components shown may be assembled by conventional means, for example, with fasteners, adhesives, welding or soldering, and the like. According to one aspect, the components of interface element 82, in a fashion similar to interface element 78, may be fabricated with hook-and-loop type fasteners, for example, by cutting the components from hook-and-loop type fastener material, for example, from sheets or strips of hook-and-loop type fasteners.

As shown in FIGS. 19 through 21, in one aspect, interface element 82 may include a base element 132 and a plurality of guide elements 134, 136 and 138 each shaped as shown and mounted to base element 132. Though base element 132 and guide elements 134, 136, and 138 are shown generally polygonal in shape with one or more rounded edges, the shapes of base element 132 and guide elements 134, 136, and 138 may vary broadly while still providing the desired function.

As shown most clearly in FIGS. 19 and 20, guide element 134 is mounted to base element 132, for example, with or without one or more spacer elements 135, and guide elements 136 and 138 are mounted to base element 132 to provide a first contact surface A on guide element 134, a second contact surface B on guide element 136, and a third contact surface C on guide element 138 as shown in FIG. 19. According to the aspect of the invention shown in FIGS. 19 through 21, contact surface A on guide element 134 may be “higher than” or distal to contact surfaces B and C, where, upon impact of the adjacent helmet shell (not shown), contact surface A receives a force, as indicated by arrow 140 in FIG. 21, and transmits the force 140 prior to contact surfaces B and C.

According to aspects of the invention, this prior contact and loading indicated by arrow 140, no matter how small the difference in contact time, promotes the reception and transmission of a load upon contact surface A on guide element 134 before the reception and transmission of the load to contact surfaces B on guide element 16 and contact surface C on guide element 138. According to aspects of the invention, it is believed that prior contact and loading on contact surface A promotes the transmission of load to the adjacent liner, for example, a fluid-containing liner, and to the fluid the liner contains, as indicate by arrow 142 in FIG. 19, at a preferred time and in a desired, previously defined direction to enhance the energy absorbing capacity of the liner or helmet/liner combination. In one aspect, interface element 82 may only include guide element 134 having contact surface A on base element 132 to provide contact surfaces A and D only.

Similarly, in one aspect, as shown most clearly in FIG. 19, guide elements 136 and 138 may be mounted to base element 132 to provide contact surfaces B and C on guide elements 136 and 138. In one aspect, contact surface D may be provided on base element 132 as shown in FIG. 19. Again, according aspect of the invention, contact surface B on guide element 136 and contact surface C on guide element 138 may be “higher than” or distal contact surface D on base element 132 and higher than, lower than, or substantially equal in elevation to contact surface A on guide element 134. According to an aspect of the invention, upon impact of the adjacent helmet shell (not shown), contact surfaces C and D (depending upon the angle of impact) receive loading after, prior to, or at substantially the same time as to contact surface A. This loading on contact surfaces B and C is represented by arrows 144 and 146, respectively, shown in FIG. 21.

In the aspect of the invention shown in FIGS. 19 through 21, contact surfaces C and D are shown located at a lower elevation of contact surface A wherein reception of load on contact surface A, as indicated by arrow 140, precedes reception of load on contact surfaces B and C, as indicated by arrows 144 and 146, respectively. In one aspect, depending, for example, upon the thickness of elements 132, 135, 134, 136, and 138, the reception of load on contact surfaces B and C (arrows 144 and 146) may follow, may precede, or may occur at substantially the same time as reception of the load (arrow 140) on contact surface A. In one aspect of the invention, at least one of contact surfaces B or C (that is, either contact surface B or contact surface C or both) may be higher than contact surface D, but lower than contact surface A, where, for example, the sequence of contact and transmission may be: surface A, then surface B and/or C, and then surface D. Again, according to aspects of the invention, this prior contact and loading, no matter how small the difference in contact time, promotes the reception and transmission of a load upon contact surfaces on interface element 82 that may be used to promote the transmission of load to the adjacent liner and to the fluid 77 the liner contains, as indicated by arrows 148 and 150, respectively, in FIG. 19 at a preferred time and in a desired, previously defined direction to enhance the energy absorbing capacity of the liner or helmet/liner combination. In one aspect, interface element 82 may only include guide element 136 and/or guide element 138 on base element 132 to provide contact surfaces B and/or C only.

FIG. 22 is top, plan view of another interface element 84 shown in FIGS. 8 and 9 according to an aspect of the invention. Interface element 84 shown in FIG. 22 may be a mirror image of interface element 80 shown in FIGS. 8 and 9 according to one aspect of the invention. FIG. 23 is a side elevation view of interface element 84 shown in FIG. 22 as viewed along view lines 23-23 shown in FIG. 22; and FIG. 24 is a side elevation view of interface element 84 shown in FIG. 22 as viewed along view lines 24-24 shown in FIG. 22.

As descried with respect to interface elements 78 and 82, interface element 84 and interface element 80 may be formed from a broad range of fabrication processes, for example, machining, stamping, 3-D printing, molding, laser cutting, and the like. In the aspect of the invention shown in FIGS. 22 through 24, interface element 84 is fabricated by multiple components to facilitate development, fabrication, and/or evaluation. In the aspect shown, the multiple components shown may be assembled by conventional means, for example, with fasteners, adhesives, welding or soldering, and the like. According to one aspect, the components of interface element 84, in a fashion similar to interface elements 78 and 82, may be fabricated with hook-and-loop type fasteners, for example, by cutting the components from hook-and-loop type fastener material, for example, from sheets or strips of hook-and-loop type fasteners.

As shown in FIGS. 22 through 24, in one aspect, interface element 84 may include a base element 152 and a plurality of guide elements 154, 156, 158, and 160, each shaped as shown and mounted to base element 152. Though base element 152 and guide elements 154, 156, 158, and 160 are shown generally polygonal in shape with one or more rounded edges, the shapes of base element 152 and guide elements 154, 156, 158, and 160 may vary broadly while still providing the desired function.

As shown most clearly in FIGS. 23 and 24, guide elements 154, 156, 158, and 160 may be mounted to base element 152, for example, with or without one or more spacer elements (not shown), and guide element 156 may be mounted to one or more guide elements 154, 158, and/or 160 to provide a first contact surface A on guide element 156, a second contact surface B on guide element 160, a third contact surface C on guide element 154, and a fourth contact surface D on guide element 158, as shown in FIG. 22. In one aspect, the surface of base element 152 may comprise a fifth contact surface E.

According to the aspect of the invention shown in FIGS. 22 through 24, contact surface A on guide element 156 is “higher than” or distal to contact surfaces B, C, D, and E, where, upon impact of the adjacent helmet shell (not shown), contact surface A receives a force, as indicated by arrow 162 in FIG. 24, and transmits loading prior to contact surfaces B, C, D, and E. According to aspects of the invention, this prior contact and loading indicated by arrow 162, no matter how small the difference in contact time, promotes the reception and transmission of a load upon contact surface A on guide element 156 before the reception and transmission of the load to contact surfaces B on guide element 160, contact surface C on guide element 154, contact surface D on guide element 158, and contact surface E on base element 152. According to aspects of the invention, it is believed that prior contact and loading on contact surface A promotes the transmission of the force 162 to the adjacent liner, for example, a fluid-containing liner, and to the fluid in the liner contains, as indicate by arrow 164, at a preferred time and in a desired, previously defined direction to enhance the energy absorbing capacity of the liner or helmet/liner combination. In one aspect, interface element 84 may only include guide element 156 having contact surface A on base element 152 to provide contact surfaces A and E only.

Similarly, in one aspect, as shown most clearly in FIG. 22, guide elements 154, 158, and 160 may be mounted to base element 152 to provide contact surfaces B, C, and D on guide elements 160, 154, and 158, respectively. In one aspect, contact surface E may be provided on base element 152 as shown in FIG. 22. Again, according to this aspect of the invention, contact surface B on guide element 160, contact surface C on guide element 154, and/or contact surface D on guide element 158 may be “higher than” or distal contact surface E on base element 152 and higher than, lower than, or substantially equal in elevation to contact surface A on guide element 156 (for example, with one or more appropriative spacer elements, not shown). According to aspect of the invention, upon impact of the adjacent helmet shell (not shown), contact surfaces B, C, D and/or E (depending upon the angle of impact) may receive loading before, after, or substantial at the same time as to contact surface A. Arrows 166 and 168 represent this loading on contact surfaces C and D, respectively, shown in FIG. 24.

In the aspect of the invention shown in FIGS. 22 through 24, contact surfaces B, C, and D are shown located at a lower elevation of contact surface A wherein reception of load on contact surface A, as indicated by arrow 162, precedes reception of load on contact surfaces B, C, and D, as indicated by arrows 166 and 168, respectively. In one aspect, depending, for example, upon the thickness of elements 152, 154, 156, 158, and 160, the reception of load on contact surfaces B, C, and D (arrows 166 and 168) may follow, may precede, or may occur at substantially the same time as reception of the load (arrow 162) on contact surface A. In one aspect of the invention, at least one of contact surfaces B, C, or D (that is, either contact surface B or contact surface C or contact surface D or all three) may be higher than contact surface E, but lower than contact surface A, where, for example, the sequence of contact and transmission may be: surface A, then surface B and/or C and/or D, and then surface E.

Again, according to aspects of the invention, this prior contact and loading, no matter how small the difference in contact time, promotes the reception and transmission of a load upon contact surfaces on interface element 84 that may be used to promote the transmission of load to the adjacent liner and to the fluid the liner contains, as indicated by arrows 170, 172, and 174, respectively, shown in FIG. 22, at a preferred time and in a desired, previously defined direction to enhance the energy absorbing capacity of the liner or helmet/liner combination. In one aspect, interface element 84 may only include one or more of guide elements 154 and/or guide element 158 and/or guide element 160 on base element 152 to provide contact surfaces B and/or C and/or D only.

In one aspect of the invention, the location, orientation, and/or direction of interface elements 78, 90, 82, and 84 on headgear liners may be chosen to direct or channel fluid flow within a liner about or around any internal structures in the fluid-filled liner. For example, as shown in FIG. 8 and FIG. 22, interface elements 84 having guide elements 154, 156, 158, and 160 may be positioned to direct flow around or past internal hole side walls 180 and 182 (shown in phantom in FIG. 22) within a fluid-filled liner (not shown). Though FIG. 22 shows this aspect for interface element 84, interface elements 78, 80, and 82 may also be located, orientated, and/or directed to provide guide elements that channel or direct flow in a direction that avoids or circumvents any internal structures within a fluid-filled liner. These internal structures may include sidewalls of holes or cavities, baffles, and liner sidewalls, among other internal structures that may be found within a liner, such as, a fluid-filled liner.

Interface elements 78, 80, 82, and 84 may comprise a broad range of materials and material surface textures. For example, in one aspect, interface elements 78, 80, 82, and 84 may comprise a plastic, for example, a polyamide (PA), for example, nylon; a polyethylene (PE), both high-density polyethylene (HDPE) and low-density polyethylene (LDPE); a polyethylene terephthalate (PET); a polypropylene (PP); a polyester (PE); a polytetrafluoroethylene (PTFE); a polystyrene (PS); an acrylonitrile butadiene styrene (ABS); a polycarbonate (PC); or a polyvinylchloride (PVC); among other plastics. In another aspect, interface elements 78, 80, 82, and 84 may comprise an elastic material, such as, a rubber or an elastomer, for example, a natural polymer, such as, polyisoprene rubber, or a synthetic polymer, such as, a neoprene, a thermoplastic elastomer, a thermoplastic rubber, and a polyvinyl chloride, or an ethylene propylene diene monomer (EPDM) rubber, and the like. In another aspect, interface elements 78, 80, 82, and 84 may comprise a wood (for example, in the form of paper) or a metal, while providing the desired reduction in friction.

In one aspect of the invention, interface elements 78, 80, 82, and 84 may be flexible or pliant, for example, readily conforming to the shape and texture of the internal surface 58 of helmet shell 52 (as shown in FIG. 7) and/or the external surface 70 of headgear liner 56 (as shown in FIG. 7). In one aspect, interface elements 78, 80, 82, and 84 may comprise a woven or unwoven fabric, for example, a natural fabric such as, cotton or wool, or a synthetic fabric, for example, fabricated from threads of any one or more of the plastics or polymers disclosed herein.

In one aspect, as disclosed herein, interface elements 78, 80, 82, and 84 and their respective guide elements may be fashioned from a hook-and-loop type fastener material, for example, the same or a different hook-and-loop type fastener material. For instance, in one aspect, interface elements 78, 80, 82, and 84 may comprise a “hook side,” a “loop side,” or both of a hook-and-loop type fastener material.

The hook-and-loop-type fasteners used for interface elements 78, 80, 82, and 84 may comprise a plastic hook-and-loop type fastener, for example, a nylon hook-and-loop type fastener, or a hook-and-loop type fastener made of any one of the plastics disclosed herein. In one aspect, the hook-and-loop type fastener used for interface elements 78, 80, 82, and 84 may be a Velcro® brand hook-and-loop-type fastener provided by Velcro, USA, for example, a nylon Velcro® hook-and-loop-type fastener having model number 158505, or its equivalent.

As disclosed herein, interface elements 78, 80, 82, and 84 may have a general rounded rectangular shape or “race track oval” type shape. In one aspect, interface elements 78, 80, 82, and 84 may have a dimension, that is, a length, width, or diameter, ranging from 0.25 inches to 12 inches, depending, among other things, upon the size of liner 56, but typically interface elements 78, 80, 82, and 84 may have a dimension ranging between 1 inch and 5 inches, for example, about 3 inches in length and about 2 inches in width. Similarly, any of the guide elements disclosed herein, for example, guide elements 94, 96, 98, 100, 102, and 104 shown in FIGS. 11 through 14, may have dimensions ranging between 0.25 inches and 5 inches, for example, about 1 to 2 inches in length and about 0.75 inch in width.

In one aspect, the thickness of interface elements 78, 80, 82, and 84 and their respective guide elements may range from 0.03125 ( 1/32) inches to 2 inches, depending, among other things, upon the size of the liner they are mounted to, but interface elements 78, 80, 82, and 84 and their respective guide elements typically may have a thickness ranging between 0.0625 ( 1/16) inches and 0.5 inches. In one aspect, the difference in height or elevation of one contact surface and another contact surface on interface elements 78, 80, 82, and 84 may range from 0.001 inches to 0.25 inches. However, the difference in height or elevation of one contact surface and another contact surface on interface elements 78, 80, 82, and 84 may typically range from 0.03125 ( 1/32) inches to 0.125 (⅛) inches.

FIG. 25 is a perspective view of a helmet assembly 200 according to a further aspect of the invention. FIG. 26 is an exploded perspective view of the helmet assembly 200 shown in FIG. 25. As shown in FIGS. 25 and 26, helmet assembly 200 includes a helmet shell 202, one or more interface elements 204 shaped to be received by and positioned in helmet shell 202, and helmet liner 206 positioned within interface element 204. As discussed above, according to aspects of the invention, an interface element may extend substantially completely over the external surface of a fluid-filled liner. Helmet assembly 200 shown in FIGS. 25 and 26 is an example of a helmet assembly having one such interface element 204 which extends substantially completely over the external surface of the fluid-filled liner 206. In one aspect, interface element 204 with or without liner 206 may be referred to as a “bump cap.”

According to this aspect, though this aspect shown in FIGS. 25 and 26 may be reoffered to as a “helmet assembly,” assembly 200 may comprise any form of headgear assembly, as disclosed herein.

Helmet shell 202 may comprise any one of the helmet shells disclosed herein. As shown in FIGS. 25 and 26, helmet shell 202 may typically include an external surface 208 and an internal surface 210. As in other aspects of the invention, helmet shell 202 may comprise any one or more of the plastics disclosed herein, for example, a polycarbonate.

As descried with respect to interface disclosed herein, one or more interface elements 204 may be formed from a broad range of fabrication processes, for example, machining, stamping, 3-D printing, molding, laser cutting, and the like. As shown in FIGS. 25 and 26, the one or more interface elements 204 typically include an external surface 212 and an internal surface 214. As also shown in FIGS. 25 and 26, interface element 204, in this case which may be referred to as a “bump cap,” may typically be sized and shaped to be received by helmet shell 202, for example, having a generally hemispherical shape reflecting the generally hemispherical shape of the internal surface 210 of helmet shell 202. However, it is envisioned that the shape and size of the one or more interface elements 204 may comprise any configuration, size, and/or shape that is compatible with the shape of the helmet shell 202 or the shape of the internal surface 210 of helmet shell 202. For example, according to an aspect of the invention where the one or more interface elements 204 provide at least some form of reduced friction between helmet liner 204 and helmet shell 202, the one or more interface elements 204 may typically be shaped where the external surface 212 of the one or more interface elements 204 is shaped to generally contact and/or bear against the internal surface 210 of helmet shell 202. In one aspect, the shape of interface elements 204 may be provided where at least 50% of the area of the external surface 212 may contact and/or bear against the internal surface 210 of helmet shell 202. In another aspect, the shape of the one or more interface elements 204 may be provided where at least 75%, or at least 90%, of the area of the external surface 212 may contact and/or bear against the internal surface 210 of helmet shell 202.

Though in FIG. 26, interface element 204 is shown as one integral part, in one aspect, interface element 204 may comprise two or more parts or components, for example, two or more separate or interlocking components. The thickness of interface element 204 may be similar to the thicknesses of any of the interface eluents disclosed herein, for example, having a thickness ranging between 0.0625 ( 1/16) inches and 0.5 inches. As in other aspects of the invention, interface element 204 may comprise any one or more of the plastics disclosed herein, for example, an ABS plastic or a PTFE-containing plastic.

As shown most clearly in FIG. 26, according to one aspect of the invention, interface element 204 may include one or more, but typically, a plurality of, projections or pins 216 from the internal surface of 214. According aspects of the invention, the one or more projections 216 are positioned and adapted to engage recesses or holes 218 in helmet liner 206. The engagement of projections 216 with recesses or holes 218 may at least partially assist in positioning and/or retaining helmet liner 206 within interface element 204. In one aspect, projections or pins 216 may be integrally formed into the surface 214 of interface element 204, for example, molded, machined, or otherwise fabricated from the same material, for example, a plastic, as interface element 214.

As also shown in FIG. 26, interface element 204 may include features or structures that assist in mounting and/or retaining the one or more interface elements 204 within helmet shell 202. For example, as shown in FIG. 26, interface element 204 may include one or more recesses, cavities, or holes 217 sized, positioned, and otherwise adapted to engage a retaining device or retaining assembly, for example, a harness, a suspension, or a retainer mounted in helmet shell 202.

Though shown generally circular cylindrical, for example, right circular cylindrical, in shape in FIG. 26, projections or pins 216 may comprise any appropriate cylindrical shape, including elliptical (or oval) cylindrical or polygonal cylindrical (including triangular, square, or hexagonal cylindrical). In one aspect, projections or pins 216 may be non-right cylindrical, for example, having a taper (for example, being frusto-conical in shape). In one aspect, the tapered shape of projections or pins 216 may assist in retaining the liner 206 within interface element 204. In one aspect, the tapered pins 216 may have a larger dimension at the bottom or at the surface 214 of interface element 204; in another aspect, the tapered pins 216 may have a larger dimension at the top or distal the surface 214 of interface element 204.

Projections or pins 216 may have width, diameter, or outer dimension ranging from about 0.0625 ( 1/16) inches to about 3 inches, but the outer dimension may typically between about 0.125 inches to about 1.5 inches. Projections or pins 216 may have length (or height from surface 214) ranging from about 0.125 inches to about 3 inches, but is typically between about 0.25 inches to about 1 inch in length.

Projections or pins 216 may be made from any one or more of the materialists disclosed herein, for example, any one or more of the plastics or elastomers disclosed herein. In one aspect, projections or pins 216 may be made of a low-density compressible material, for example, a plastic foam material, such as, expanded polypropylene (EPP), or its equivalent.

As shown in FIGS. 25 and 26, helmet liner 206 may be any liner or interface shaped and adapted to be received by interface element 204 and the head of a wearer (not shown). As shown in FIG. 26, helmet liner 206 may typically include an external surface 220 and an internal surface 222. Helmet liner 206 may comprise any one of the fluid-containing liners disclosed herein, for example, liner 16 or liner 56 disclosed herein, or a fluid-filled headgear liner disclosed in U.S. Pat. No. 8,856,972 or U.S. Pat. No. 10,531,699; or in pending U.S. application Ser. Nos. 16/595,135; 16/738,234; 17/020,888; or 17/015,738. Helmet liner 206 may be formed from a liquid silicone rubber (LSR), for example, a cured LSR. In one aspect, helmet liner 206 may be comprise a “medical grade” LSR, as known in the art, for example, a LSR marketed by CHT USA (formerly Quantum Silicones (QSi)) under the trademark True Skin® or its equivalent; however, helmet liner 206 may comprises any liquid silicone rubber (LSR).

In one aspect, the fluid in helmet liner 206 may comprise a polydimethylsiloxane fluid, for example, a polydimethylsiloxane fluid marketed by CHT USA as a QM Diluent or its equivalent; however, liquid 14 may comprise any polydimethylsiloxane fluid. However, in other aspects, the fluid in helmet liner 206 may be any fluid, including an oil or water, such as, distilled water.

FIG. 27 is a plan view of the fluid-filled helmet liner 206 shown in FIG. 26. As shown in FIGS. 26 and 27, helmet liner 206 may comprise a central portion and a plurality of “lobes” 226 extending from the central portion 224, the lobes 226 may be delimited by radial recesses 228. According to an aspect of the invention, the central portion 224, lobes 226, and recesses 228 allow the typically malleable liner 206 to be manipulated and shaped to be inserted within the interface element ^204.

As also shown in FIG. 27, helmet liner 226 may include recesses or holes 218 shaped and positioned to engage projections or pins 216, as disclosed herein. Recesses 218 may extend through liner 226, for example, through holes, or may comprise recesses, for example, “blind holes,” in liner 226. The dimension of recesses or holes 218 may be comparable to the dimension of projections 216, for example, to ensure elastic engagement. For example, recesses or holes 218 may be circular, elliptical, or polygonal in cross section, and may have an inside diameter or inside dimension ranging from about 0.0625 ( 1/16) inches to about 3 inches, but the outer dimension of recesses or holes 218 may typically between about 0.125 inches to about 1.5 inches.

As also shown in FIG. 27, helmet liner 226 may include recesses or holes 230, for example, extending through the liner 226. Holes 230 may be circular or non-circular in cross section, and have an inside diameter or dimension ranging from 0.125 inches to 3 inches, but typically have an inside dimension ranging from 0.25 inches to 1 inch.

As disclosed herein, helmets, headgear, headgear liners, helmet liner assemblies, and methods of protecting the head are provided having interface elements, for example, friction-reducing interface elements or pads having load directing guide elements that enhance head protection and provide improvements over the existing helmet or headgear technology.

Though aspects of the invention may have been described in the context of helmets or headgear, it is envisioned that aspects of the invention can be applied to any form of head protection that could benefit from aspects of the invention. For example, it is envisioned that aspects of the invention may be implemented in, and thus may comprise, a baseball catcher's helmet, a baseball batter's helmet, a soft ball catcher's helmet, a softball batter's helmet, a hockey helmet, a hockey goalie mask, a motorcycle helmet, a motor cross helmet, a skiing helmet, a snowboarding helmet, a skateboarding helmet, a lacrosse helmet, a bicycle helmet, a jockey helmet, an official's helmet, a medical protection helmet, a rock or ice climbing helmet, a mining helmet, a mountain climbing helmet, a football helmet, a construction helmet, a hard hat, and a military helmet, among others. It is also envisioned that aspects of the invention may be implemented in, and thus may comprise, a bump cap, as known in the art.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present disclosure has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the disclosure in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the disclosure. The embodiments were chosen and described in order to best explain the principles of the disclosure and the practical application, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated.

While several embodiments and aspects of the present invention have been described and depicted herein, alternative aspects may be affected by those skilled in the art to accomplish the same objectives. Accordingly, it is intended by the appended claims to cover all such alternative aspects as fall within the true spirit and scope of the invention.

	Number	Date	Country
	63036006	Jun 2020	US
	63198714	Nov 2020	US

HEADGEAR ASSEMBLIES AND HEADGEAR LINERS HAVING FRICTION-REDUCING INTERFACE ELEMENTS

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CROSS-REFERENCE TO RELATED APPLICATIONS

Provisional Applications (2)