HELMET LINER ASSEMBLY

Abstract

A helmet having a helmet shell with an inner surface defining a cavity and a frontal opening is provided. The helmet includes a liner assembly for engagement with the helmet shell within the cavity, and which has a lateral liner portion including left and a right liner portions having an outer surface complementarily shaped relative to left and right inner surface portions of the inner surface, respectively. The left liner portion includes a left chin segment, and the right liner portion includes a right chin segment, with the chin segments being configured to engage one another proximate a front section of the helmet. The liner assembly also includes a central liner portion engageable between the left and right liner portions and having an outer surface complementarily shaped relative to a central portion of the inner surface portion for engagement therewith.

Description

TECHNICAL FIELD

The technical field generally relates to helmets, and more particularly to helmets provided with a reinforced liner assembly.

BACKGROUND

Helmets used for outdoor activities typically include a shell that defines a cavity for housing a wearer's head, and a front opening to allow the wearer to see. The helmets also include a liner, or liner assembly, lining the inner surface of the shell to provide increased comfort and/or security to the wearer. Typical liner assemblies can include a foam piece in the general shape of the helmet shell. The foam piece can then be trimmed down to have the liner fit into the cavity. However, this process can leave gaps between the liner and the inner surface of the shell, thereby reducing the efficiency of the liner assembly.

Known liner assemblies can also be made of a plurality of pieces configured to engage one another within the cavity of the shell. These pieces of the liner assembly can be individually trimmed, or connected to one another via adhesive or other components, then subsequently trimmed. This process can be generally more complex, which can cause increased manufacturing time, along with increased labour costs.

There is therefore a need for a helmet provided with a liner assembly adapted to overcome at least some of the drawbacks of what is known in the field.

SUMMARY

According to an aspect, a helmet is provided. The helmet includes a helmet shell having an inner surface defining a cavity and a frontal opening. The helmet also includes a liner assembly for engagement with the helmet shell within the cavity, including a lateral liner portion including a left liner portion and a right liner portion, where each of the left and right liner portions has an outer surface complementarily shaped relative to left and right inner surface portions of the inner surface, respectively, and configured to engage with same, where the left liner portion includes a left chin segment, and the right liner portion includes a right chin segment. The left and right chin segments being configured to engage one another proximate a front section of the helmet shell. The liner assembly also has a central liner portion engageable between the left and right liner portions and having an outer surface complementarily shaped relative to a central inner surface portion for engagement therewith.

According to a possible embodiment, the complementarily shaped outer surfaces of the left and right liner portions and the left and right inner surface portions are adapted to engage one another to at least partially reduce relative movement between the left and right liner portions and the helmet shell.

According to a possible embodiment, the central liner portion includes central engagement surfaces provided on either side thereof, and wherein the left and right liner portions include respective lateral engagement surfaces configured to engage with the central engagement surfaces.

According to a possible embodiment, central engagement surface includes one or more projections extending therefrom, and where each lateral engagement surface includes one or more recesses adapted to receive respective projections therein, the projections and recesses being adapted to cooperate to at least partially reduce relative movement between the central liner portion and the left and right liner portions.

According to a possible embodiment, the central engagement surfaces are shaped and sized to bias the left and right liner portions outwardly and away from the central liner portion upon engagement of the central liner portion between the left and right liner portions.

According to a possible embodiment, the central liner portion includes rabbeted edges extending along left and right sides thereof.

According to a possible embodiment, the central engagement surfaces each rabbeted edge includes at least one angled surface define a wedge configured to bias the left and right liner portions outwardly and away from the central liner portion upon engagement of the central liner portion between the left and right liner portions.

According to a possible embodiment, the rabbeted edges extend along an entire length of the left and right sides of the central liner portion.

According to a possible embodiment, the left and right liner portions each include an overhang adapted to engage respective rabbeted edges and define rabbet joints therewith.

According to a possible embodiment, the rabbet joints extend along the entire length of the left and right sides of the central liner portion.

According to a possible embodiment, the helmet further includes a bottom opening, and wherein the central liner portion extends from a rear section of the helmet shell proximate the bottom opening, along the central inner surface portion and to the front section proximate the frontal opening.

According to a possible embodiment, the central liner portion includes a frontal segment adapted to be spaced from the inner surface of the helmet shell, thereby defining a gap therebetween.

According to a possible embodiment, the left and right liner portions include respective forward segments adapted to be spaced from the inner surface of the helmet shell, and wherein the gap is further defined between the inner surface of the helmet shell and the forward segments.

According to a possible embodiment, the front segment and the forward segments are adapted to define a continuous surface when the central liner portion is coupled between the left and right liner portions.

According to a possible embodiment, the helmet further includes a chin guard provided at the front section of the helmet shell and at least partially defining a periphery of the frontal opening, and wherein the left and right chin segments extend along the chin guard on respective sides thereof and engage one another substantially at a middle point of the chin guard.

According to a possible embodiment, each one of the left and right chin segments includes an engagement surface adapted to engage the engagement surface of the other one of the left and right chin segments.

According to a possible embodiment, one of the engagement surfaces includes a protrusion, and wherein another one of the engagement surfaces includes a recess adapted to receive the protrusion therein when the engagement surfaces engage one another.

According to a possible embodiment, the engagement surfaces are substantially flat or planar.

According to a possible embodiment, the engagement surfaces are substantially perpendicular relative to the chin guard proximate the middle point.

According to a possible embodiment, each one of the left liner portion, the right liner portion and the central liner portion is made of a single piece.

According to a possible embodiment, each one of the left liner portion, the right liner portion and the central liner portion is made via a molding process or an additive manufacturing process.

According to a possible embodiment, the liner assembly is made of expanded polystyrene (EPS).

According to a possible embodiment, the helmet further includes a chin brace coupled to the left and right chin segments to reinforce the left and right chin segments within the cavity.

According to a possible embodiment, the chin brace extends along the periphery of the frontal opening.

According to a possible embodiment, the chin brace is coupled to the left and right chin segments via at least one fastener.

According to another aspect, a helmet liner assembly for installation within a cavity of a helmet shell along an inner surface thereof is provided. The liner assembly includes a lateral liner portion including a left liner portion and a right liner portion, each of the left and right liner portions having an outer surface complementarily shaped relative to left and right inner surface portions of the inner surface, respectively, and configured to engage with same, where the left liner portion includes a left chin segment, and the right liner portion includes a right chin segment, the left and right chin segments being configured to engage one another proximate a front section of the helmet shell; and a central liner portion engageable between the left and right liner portions and having an outer surface complementarily shaped relative to a central inner surface portion for engagement therewith.

According to another aspect, a method of installing a helmet liner assembly as defined above is provided. The method includes inserting the left liner portion within the cavity for engagement with a left inner surface portion; inserting the right liner portion within the cavity for engagement with a right inner surface portion; and inserting the central liner portion within the cavity between the left and right liner portions for engagement therewith.

According to a possible embodiment, the steps of inserting the left liner portion and the right liner portion within the cavity are done generally simultaneously.

According to another aspect, a method for installing a helmet liner assembly within a helmet shell is provided. The method includes inserting a left liner portion made of a single piece of material within a cavity of the helmet shell for engagement with a left inner surface portion thereof; inserting a right liner portion made of a single piece of material within the cavity for engagement with a right inner surface portion thereof; and inserting a central liner portion made of a single piece within the cavity between the left and right liner portions for engagement therewith, the central liner portion being configured to bias the left and right liner portions against corresponding inner surface portions of the helmet shell when engaged between the left and right liner portions.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a helmet having a helmet shell and a liner assembly, according to an embodiment.

FIG. 2 is a perspective view of the helmet shown in FIG. 1, showing the liner assembly (left) separated from the helmet shell (right).

FIGS. 3 and 4 are right-side and left-side exploded perspective views of the liner assembly shown in FIG. 2, showing a central liner portion provided between left and right liner portions, according to an embodiment.

FIG. 5 is a perspective view of the central liner portion shown in FIGS. 3 and 4, according to an embodiment.

FIG. 6 is a front view of the helmet shown in FIG. 1.

FIG. 7 is a left-side view of the helmet shown in FIG. 1.

FIG. 8 is a cross-sectional view of the helmet shown in FIG. 6, taken along the line 8-8.

FIG. 9 is a cross-sectional view of the helmet shown in FIG. 7, taken along the line 9-9.

FIGS. 10 and 11 are respectively left-side and right-side perspective views of the liner assembly according to an embodiment, showing a chin brace coupled to the liner assembly.

FIG. 12 is a perspective view of another embodiment of a helmet, the helmet being provided with a breathguard.

FIG. 13 is a top cross-sectional of another embodiment of the helmet, showing a ventilation conduit defined in a thickness of the helmet shell.

FIGS. 14 and 15 are cross-sectional views of a helmet provided with the liner assembly shown in FIG. 3, showing a gap defined between the central liner portion and the helmet shell and visors positioned in a lowered position (FIG. 14), and showing a secondary visor positioned in a raised position within the gap (FIG. 15).

FIG. 16 is a cross-sectional view of the helmet, showing forces applied to various parts of the helmet when worn by a wearer, according to an embodiment.

FIGS. 17 to 23 are various perspective views of the helmet, illustrating an exemplary method for installing the liner assembly within the helmet shell, with the left and right liner portions being initially inserted within the helmet shell (FIGS. 17 and 18) and positioned against corresponding sides of the helmet shell (FIGS. 19 and 20), and with the central liner portion being subsequently inserted within the helmet shell between the left and right liner portions (FIGS. 21 to 23).

FIG. 24 is a perspective view of the liner assembly shown in FIGS. 10 and 11, showing a chin brace secured to the left and right liner portions via fasteners, according to an embodiment.

DETAILED DESCRIPTION

As will be explained below in relation to various embodiments, the present disclosure describes a helmet for use in various activities and sports, such as snowmobiling, for example. The helmet includes a helmet shell provided with a liner assembly installed within a cavity defined by the helmet shell. The liner assembly is complementarily shaped and engages the inner surface of the helmet shell (e.g., the surface defining the cavity) which at least partially reduces relative movement between the liner assembly and the helmet shell. In some embodiments, the liner assembly includes a plurality of portions engaging and interlocked with one another to facilitate insertion of the liner assembly within the cavity. For example, one portion of the liner assembly can be inserted within the cavity at a time, which can then be interlocked and assembled within the cavity. The liner assembly can further define a self-locking assembly whereby interlocking the portions of the liner assembly to one another at least partially secures the portions together and within the cavity.

With reference to FIGS. 1 and 2, a helmet 10 is shown in accordance with a possible embodiment. In this embodiment, the helmet 10 includes a protective helmet shell 12 having an inner surface 14 defining a cavity 16 shaped and configured to receive a wearer's head, such as via a bottom opening 20. The helmet shell 12 further defines a front opening 18 communicating with the cavity 16 in order to allow the wearer to see. In this embodiment, the helmet 10 has a liner assembly 100 provided within the cavity 16 for engaging the inner surface 14 of the helmet shell 12. It is appreciated that the liner assembly 100 can define a protective structure to be installed within the cavity 16 to improve comfort and protection of the wearer. The liner assembly 100 can be a soft or padded lining made of Expanded Polystyrene (EPS) foam, for example. However, it is appreciated that other configurations and/or material can be used to provide a liner to the helmet 10.

In the illustrated embodiment, the helmet 10 is a full-face type helmet, where the chin guard 22 forms part of the helmet shell 12 (i.e., the chin guard is static). Having a static chin guard reduces the weight of the helmet 10 since the chin guard 22 does not require a pivoting/rotating mechanism, such as a hinge, to pivotally connect the chin guard 22 to the helmet shell 12. By reducing the weight of the helmet 10, the stress applied to the wearer's head and neck can accordingly be reduced, thus increasing overall comfort when wearing the helmet 10. However, it is appreciated that the liner assembly described herein can be used with other types of helmets than full-face type helmets.

As seen in FIGS. 2, 3 and 4, the liner assembly 100 can include a plurality of liner portions adapted to be connected to one another. In this embodiment, the liner assembly 100 includes a lateral liner portion 102, and a central liner portion 110 configured to engage one another to form an overall structure of the liner assembly 100. The lateral liner portion 102 can be adapted to engage lateral portions of the inner surface 14 of the helmet shell 12, and the central liner portion 110 can be adapted to engage a central portion of the inner surface 14. It should be understood that, as used herein, the lateral portions can refer to sections of the liner assembly adapted to cover at least the temporal regions of the wearer's head, which can include the ears, the temples, the cheeks, portions of the back of the head, portions of the jaw and/or portions of the chin, among others.

In some embodiments, the lateral liner portion 102 can include a left liner portion 104 and a right liner portion 106 adapted to engage respective lateral portions of the inner surface 14 of the helmet shell 12. More specifically, the left liner portion 104 is adapted to engage a left inner surface portion, and the right liner portion 106 is adapted to engage a right inner surface portion. The central liner portion 110 is illustratively provided between the left and right liner portion 104, 106 and engages a central inner surface portion of the inner surface 14. The central liner portion 110 is further adapted to engage the lateral liner portion (e.g., the left and right liner portions 104, 106), as will be described further below.

In this embodiment, the left and right liner portions 104, 106 each include an outer surface complementarily shaped relative to the corresponding inner surface portion. This configuration can at least partially reduce relative movement between the left and right liner portions and the helmet shell 12. More particularly, the left liner portion 104 can engage the left inner surface portion such that the complementarily-shaped features engage one another to prevent, or at least reduce movement of the left liner portion relative to the left inner surface portion. It is appreciated that the same is applicable for the right liner portion 106 in relation with the right inner surface portion, and for the central liner portion 110 in relation with the central inner surface portion.

In some embodiments, the helmet shell 12 includes helmet mounting sections 30 used in relation with a visor assembly (shown in FIGS. 2 and 9), where components used for pivotally connecting one or more visors are coupled to the helmet on or around the helmet mounting sections 30. As seen in FIG. 9, the helmet mounting sections 30 are depressed on the helmet shell and at least partially extend within the cavity 16. As such, the complementarily-shaped portion of the left and/or right liner portions 104, 106 are configured to cooperate with the inwardly extending part of the helmet mounting sections 30, which contributes to blocking relative movement between the liner portions and the helmet shell. It should be noted that the central liner portion 110 can similarly engage a corresponding profile which can be defined along the central inner surface portion, for example, to block relative movement therebetween when engaged together.

In this embodiment, the shape and size of the lateral portions of the liner assembly 100 can assist in preventing disengagement of the liner assembly 100 from within the cavity 16. For example, the left and right liner portions 104, 106 extend higher and lower within the cavity 16 than the widest point of the helmet. This feature enables the left and right liner portions 104, 106 to “sit” along their respective inner surface portions and further reduces relative movement between the liner portions and the helmet shell. In addition, the helmet shell can include a bottom lip 40 defined about a periphery of the bottom opening 20, as illustrated in FIGS. 8 and 9. The bottom lip can be adapted to prevent disengagement of the liner assembly 100 from within the cavity once installed along the inner surface (or at least reduce the risks thereof). As seen in FIGS. 8 and 9, the bottom lip 40 can extend inwardly toward the cavity 16 to enable respective bottom sections of the liner portions to sit thereon. As such, downward movement of the liner assembly 100 (e.g., toward the bottom opening 20) is at least partially prevented.

With reference to FIGS. 3 and 4, the central portion can include central engagement surfaces 112 extending along a given length on either side thereof. The left and right liner portions 104, 106 include respective lateral engagement surfaces 114, 116 configured to engage with the central engagement surfaces 112. In other words, the lateral liner portions (e.g., the left and right liner portions 104, 106) are adapted to be removably coupled to the central liner portion 110 via an engagement of the engagement surfaces with one another. In this embodiment, the central engagement surfaces 112 and the lateral engagement surfaces 114, 116 can include complementarily-shaped features configured to define an interlocking relationship between the liner portions, and thus enable interlocking the liner portions together.

The complementarily-shaped features can also be adapted to assist in positioning the liner portions relative to one another and facilitate coupling the liner portions together in the desired configuration. For example, the central liner portion 110 can be provided with one or more projections 115 extending from the central engagement surfaces 112, and the left and right liner portions can be provided with corresponding recesses 125 shaped and sized to receive the projections 115 therein. The projections 115 can be adapted to prevent, or at least reduce relative movement between the corresponding lateral liner portion and the central liner portion 110 when engaged together.

As seen in FIGS. 1 and 3 to 5, the central engagement surfaces 112 can extend along substantially the entire length of the central liner portion 110. In this embodiment, the central liner portion 110 is arcuate to conform to the inner surface 14 of the helmet shell 12, and includes a rear end 110a adapted to be positioned proximate the bottom opening 20 at a back section 15 of the helmet shell 12, and a front end 110b adapted to be positioned proximate an upper periphery 19 of the front opening 18 (seen in FIG. 1). In some embodiments, the projections 115 and recesses 125 can be spaced along the length of the central and lateral engagement surfaces 112, 114, 116 to define a plurality of engagement joints on each side of the central liner portion 110. It is noted that the engagement joints defined on a left side of the central liner portion 110 can be aligned with the engagement joints defined on a right side thereof. In other words, the projections 115 are axially aligned with one another on opposite sides of the central liner portion 110. However, it is appreciated that other configurations are possible and may be used to assist in positioning the liner portions relative to one another and facilitate coupling the liner portions together in the desired configuration.

In this embodiment, the projections 115 are generally cone-shaped and include a base tapering inwardly to an apex, with the recesses 125 being complementarily shaped for receiving the cone-shaped projections. It should be understood that the projections 115 and recesses 125 can have other shapes and configurations enabling engagement with one another, such as rectangular, semi-circular, triangular, frustoconical, etc., for example. It should thus be noted that the liner portions can be secured within the cavity of the helmet shell 12 without the use of adhesives or fasteners. The liner portions are held in place relative to one another via the interlocking and complementarily-shaped features (e.g., projections 115 and recesses 125) to form the liner assembly 100, and the liner assembly 100 is held in place within the cavity 16 via the complementarily-shaped outer surface of the liner assembly 100 and inner surface 14 of the helmet shell 12.

With reference to FIG. 9, in addition to FIGS. 3 to 5, the central liner portion 110 can include a rabbeted edge 120 defined and extending along the left and right sides thereof (e.g., similar to the central engagement surfaces 112). The rabbeted edges 120 can include a pair of surfaces angled relative to one another by any suitable angle. For instance, the rabbeted edges 120 can include a first surface 121, which can be generally vertical, and a second surface 123, which can be generally horizontal, connected to one another to form the rabbet. In some embodiments, the first surface 121 can be parallel to the central engagement surfaces 112, although other configurations are possible. As will be described further below, the second surface 123 can be angled relative to the first surface 121 such that the angle defined therebetween differs from a right angle. For instance, the second surface 123 can extend downwardly (e.g., the angle is greater than 90 degrees) which can enable the central liner portion 110 to wedge and bias the lateral liner portions outwardly.

In this embodiment, the left and right liner portions 104, 106 respectively include an overhang 124, 126 adapted to extend inwardly (e.g., toward one another) within the cavity 16. The overhangs 124, 126 can be configured to contact and engage the rabbeted edges 120 on respective sides to define rabbet joints 128 along the length of the central liner portion 110. In some embodiments, the formed rabbet joints 128 can extend along the entire length of the central liner portion 110 (e.g., from the rear end 110a to the front end 110b) and are generally symmetrical on either side of the central liner portion 110. It should be understood that the rabbeted edges 120 of the central liner portion 110 and the overhangs 124, 126 of the left and right liner portions can be part of the complementarily-shaped features previously described, along with the projections 115 and recesses 125, for example. In some embodiments, the rabbeted edges 120, the overhangs 124, 126 and the lateral engagement surfaces 114, 116 can cooperate to define a stepped joint (e.g., in the shape of a staircase) between the central liner portion 110 and each of the left and right liner portions 104, 106.

Still referring to FIGS. 3, 4 and 9, the surfaces 121, 123 of the rabbeted edge 120 can be angled relative to each other in a manner such that the central liner portion 110 is configured to bias the lateral liner portions 104, 106 toward the helmet shell (e.g., away from the central liner portion 110). In this embodiment, the angled surfaces of the rabbeted edge 120 can define a wedge 130 configured to bias the left liner portion 104 and the right liner portion 106 towards the left and right inner surface portions, respectively. As such, it is noted that the engagement of the central liner portion 110 between the lateral liner portions 104, 106 forms the liner assembly 100 and simultaneously assists in securing the liner assembly 100 within the cavity 16. In this embodiment, the outwardly oriented biasing force generated by the wedge 130 of the central liner portion 110 is sufficient to maintain the lateral liner portions 104, 106 in engagement with respective sides of the helmet shell without disengaging the projections 115 from the recesses 125 (i.e., without disengaging the lateral engagement surfaces 114, 116). In some embodiments, the central engagement surface 112 is angled and adapted to generate an outwardly biasing force, similar to the one generated by the surface(s) of the rabbeted edges 120.

Referring FIGS. 3 to 7, the left and right liner portions 104, 106 include left and right chin segments 105, 107, respectively. In this embodiment, the chin segments 105, 107 extend along the chin guard 22 on respective sides thereof and engage one another proximate a front section 13 of the helmet shell 12. The chin segments 105, 107 are adapted to engage one another such that they extend along a lower periphery 21 of the front opening 18. In some embodiments, the chin segments 105, 107 engage one another substantially at a middle point of the chin guard 22, although other configurations are possible. It is thus noted that the left and right liner portions 104, 106 can be generally symmetrical relative to a central plane, which corresponds to the location where the chin segments 105, 107 engage one another.

The left and right chin segments 105, 107 can include engagement surfaces 144, 146 configured to contact and engage one another when assembling the liner assembly 100 within the helmet shell 12. The engagement surfaces 144, 146 can be relatively flat or planar and, in some embodiment, are configured to engage one another in the central plane, although other configurations are possible, such as having angled engagement surfaces, for example. In a similar fashion as the previously described central and lateral engagement surfaces 112, 114, 116, the engagement surfaces of the chin segments 105, 107 can be provided with complementarily-shaped features configured to assist in positioning the chin segments 105, 107 relative to one another and facilitate coupling the chin segments together in the desired configuration.

As seen in FIGS. 3 and 4, the engagement surface of one of the chin segments 105, 107 can include a protrusion 145, and the engagement surface of the other one of the chin segments 105, 107 can include a recess 155, or notch, configured to receive the protrusion 145 therein. As such, it is noted that inserting the protrusion 145 within the recess 155 assists in positioning the chin segments 105, 107 relative to each other. In this embodiment, the chin segments include a single protrusion 145, and a single recess 155, although other configurations and/or complementarily-shaped features are possible and may be used. For example, complementarily shaped hooks and edges can be defined and configured to secure the chin segments to one another (e.g., without the use of adhesive or additional fasteners).

Now referring to FIGS. 10 and 11, the helmet 10 can be provided with a chin brace 24 coupled to the liner assembly 100 and configured to reinforce a portion thereof. More specifically, the chin brace 24 is adapted to be connected to the lateral liner portions and extend along at least a portion of the chin segments 105, 107 for reinforcing purposes. In this embodiment, the chin brace 24 covers the chin segments within the cavity, and includes a top edge extending along the periphery of the front opening 18, as seen in FIG. 1. In some embodiments, the chin brace 24 can be adapted to reinforce other sections of the lateral liner portions (e.g., the left and right liner portions) in addition to the chin segments 105, 107. As seen in FIGS. 10 and 11, the chin brace 24 can be coupled to the left and/or right liner portions via one or more fasteners 160, although other means of connecting the chin brace 24 can be used. The fastener 160 can be configured to extend through the chin brace, the chin segment and the chin guard 22, thereby securing these components together (i.e., thereby further securing the corresponding liner portion relative to the helmet shell).

It should be noted that integrating the chin segments of the liner assembly 100 with the lateral liner portions (e.g., with the left and right liner portions) increases control of the overall size of the liner assembly and improves cooperation with the internal features of the helmet shell (e.g., inner surface, etc.). Other components can benefit from the absence of joints or connectors between the chin segment(s) and the lateral liner portions, and the inclusion of the chin brace for increased rigidity and support. For example, and with reference to FIG. 12, in some embodiments, the helmet 10 can include a visor assembly 200, which can include a breathguard, or breathbox 204 coupled to an inner side of the visor 202, such as along a lower edge thereof. The breathguard can thus be adapted to cooperate with the lower periphery of the front opening 18 of the helmet shell and/or with the chin segments. As such, having better defined, configured and/or sized chin segments (e.g., due to their integration with the lateral liner portions) can improve cooperation and facilitate coupling between the components of the visor assembly 200 and the liner assembly 100, for example. An exemplary visor assembly including a breathguard is described in U.S. Pat. No. 11,297,891, the content of which is incorporated by reference herein in its entirety. A breath deflector can alternatively, or additionally be provided within the cavity, allowing for redirecting the wearer's breath (e.g., away from the inner surface of the visor).

In some embodiments, having better defined, configured and/or sized chin segments can facilitate positioning other components, such as ventilation conduits defined through the liner and/or helmet shell. For example, and with reference to FIG. 13, a conduit 216 can be defined within a thickness of the helmet shell 12 of the liner or a combination thereof. The conduit can have an inlet 212 communicating with the cavity to draw in breath from the wearer, for example, and one or more outlets 214, 214B, 214C defined at the rear of the helmet and communicating with the environment to expel the airflow from within the cavity to outside. Therefore, it is noted that having integrated chin segments can facilitate the addition of airflow conduits, among other possibilities. An exemplary ventilation system including airflow conduits is described in U.S. Pat. No. 11,202,482, the content of which is incorporated by reference herein in its entirety.

With reference to FIGS. 2 to 5, 8, along with FIGS. 14 to 16, the helmet 10 can include the visor assembly 200 which can include a pair of visors, such as a main visor 202, and a secondary visor 206 positioned generally behind the main visor 202. In some embodiments, the secondary visor 206 corresponds to a sun visor, which can be used when required (e.g., by covering a portion of the front opening 18, as seen in FIG. 14), and otherwise stored within the helmet shell away from the front opening 18, as seen in FIG. 15. In this embodiment, the central liner portion 110 includes a frontal segment 140 shaped and adapted to be spaced from the inner surface 14 of the helmet shell 12, thereby defining a gap 142 therebetween. The gap 142 can be adapted to receive and house the sun visor 206 when desired (e.g., when the sun visor 206 is not required). In other words, the sun visor 206 can be selectively rotated upwardly and moved within the gap 142 defined between the liner assembly 100 and the helmet shell 12.

As seen in FIGS. 2 to 5, the lateral liner portions 104, 106 can be similarly provided with forward segments 147, 149 adapted to be spaced from the inner surface of the helmet shell 12, such that the gap is further defined between the inner surface of the helmet shell 12 and the forward segments 147, 149. It should thus be noted that the forward segments 147, 149 and the frontal segment 140 can cooperate to form a continuous surface when the liner assembly 100 is assembled. As such, it is noted that the frontal segment 140 of the central liner portion 110 engages and cooperates with the forward segments provided laterally thereto, which can be adapted to reinforce and provide support on either side of the frontal segment 140.

As seen in FIG. 16, when wearing the helmet, the head of the wearer/user can apply a force or pressure on the front section of the liner assembly 100, such as on the frontal segment 140 of the central liner portion. If unsupported, the frontal segment 140 can, under the effect of the applied pressure, bend outwardly within the gap 142 (e.g., the frontal segment can flex about point A). This can cause damage to and/or malfunction of the sun visor 206 or related mechanisms positioned within the gap 142. However, by supporting the frontal segment 140 with the corresponding segments of the lateral liner portions, the movement of the frontal segment caused by pressure applied from within the helmet is negated, or at least partially reduced. This can increase the lifespan of the liner assembly 100 by reducing undesired movement of one or more portions thereof, and similarly increase lifespan of the sun visor 206 since damage can be avoided or at least reduced. It is also noted that, by reducing or preventing the bending motion of the frontal segment 140 due to internal pressures, the gap 142 can remain relatively narrow, thereby reducing the overall required size of the helmet.

Referring to FIGS. 17 to 23, the liner assembly 100 can be assembled following various methods. For instance, in one embodiment, the left and right liner portions 104, 106 can be inserted together within the cavity 16 through the bottom opening 20 (FIG. 17). As illustrated, in order to facilitate insertion, the rear section of the left and right liner portions 104, 106 can be inserted first, followed by a rotation of the left and right liner portions 104, 106 in the desired orientation (FIG. 18). In this embodiment, the desired orientation includes an alignment between the chin guard 22 and the chin segments 105, 107, among others. Once the lateral liner portions are in the desired orientation, the left and right liner 104, 106 portions can be separated within the cavity 16 (e.g., following arrows S1 and S2 seen in FIG. 19) to engage respective lateral inner surface portions of the helmet shell 12 (FIG. 20). The left and right liner portions 104, 106 are complementarily shaped relative to the lateral inner surface portions and can thus at least partially self-lock into position by engaging one or more complementarily-shaped features. It is noted that separating the left and right liner portions includes separating temporal regions thereof, while the chin segments engage one another along the chin guard. It is appreciated that the chin segments can alternatively be made to engage one another during insertion of the liner portions within the cavity or at least be drawn closer to each other to minimize their overall volume and facilitate their insertion within the cavity (seen in FIG. 17).

With the lateral liner portions 104, 106 in position within the cavity 16, the central liner portion 110 can be inserted through the bottom opening 20 to engage between the previously installed left and right liner portions (FIG. 21). In some embodiments, the central liner portion 110 is wedged between the lateral liner portions to assemble the liner assembly 100 and secure the assembled liner assembly 100 within the cavity 16 (e.g., following arrow S3 seen in FIG. 21). In this embodiment, the central liner portion 110 is inserted between the lateral liner portions in order to have the outer surface thereof engage the inner surface of the helmet shell 12, and to further have the projections 115 engage the recesses (e.g., following arrows S4 and S5 in FIG. 22) for coupling the central and lateral liner portions together (FIGS. 22 and 23). The chin brace can then be coupled to the liner assembly 100 to reinforce the corresponding portions thereof. However, as seen in FIG. 24, the chin brace 24 can be connected and/or secured to the lateral liner portions, 106 prior to inserting the central liner portion 110. As such, the lateral liner portions 104, 106 are further secured in position within the cavity and relative to one another, which can facilitate the insertion and positioning of the central liner portion 110.

In this embodiment, the liner assembly 100 is formed of three single-piece units, which are designed and configured to take up as much space as possible along the inner surface of the cavity. Having bigger pieces of the liner assembly 100 can facilitate assembly (e.g., fewer pieces to assemble), and improve connection of the liner assembly 100 to the helmet shell 12. In other words, inserting the central liner portion 110 between the left and right liner portions 104, 106 can tighten the liner assembly 100 within the cavity 16, thereby acting as a self-locking mechanism to secure the liner assembly 100 relative to the helmet shell 12. As mentioned, each liner portion can be made of a single piece of material, such as expanded polystyrene (EPS), for example, and can be manufactured using any suitable method, such as via a molding process. It should be noted that other materials can be used, and that other manufacturing methods can be employed to create the liner pieces, such as via an additive manufacturing process (e.g., 3D printing).

It should be appreciated from the present disclosure that the various embodiments of the helmet, liner assembly and related components enable for a more robust helmet, with a simplified method of assembling and installing the liner assembly within the helmet shell. The liner assembly is shaped and configured to complement the inner surface of the helmet shell. As such, gaps and misalignments are minimized or completely prevented, which can provide additional comfort and protection to the wearer of the helmet. By complementing the inner surface of the helmet shell, the liner assembly is also constrained and held in position, i.e., there is practically no relative movement between the helmet shell and the different portions of the liner assembly. It is noted that the liner assembly is constrained and secured without the use of an adhesive or additional/external fasteners.

The central liner portion advantageously engages between the left and right liner portions in an interlocking manner to form a robust liner assembly which holds together well, while also biasing the left and right liner portions away from the central liner portion and in engagement with respective inner surface portions. As such, the central liner portion acts as a wedge between the lateral liner portions, but also defines a self-locking mechanism of the liner assembly for securing it within the helmet shell, and without the use of adhesives. Further, when wearing the helmet, the central liner portion extends from the occipital region to the frontal region of the wearer, thereby providing increased protection. The central liner portion is also supported on either side thereof by the rabbet joints defined between the central and lateral liner portions, and by the projections and recesses. In other words, the central liner portion does not include a cantilevered portion, which can bend, or otherwise flex, and cause malfunctions and damages to other components of the helmet.

Finally, by integrating the chin segments to the temporal region of the lateral liner portions, the helmet has a reinforced chin portion of the helmet, which provides improved protection proximate the front section (e.g., around the chin and jaw of the wearer). The integrated chin segments also benefit other components and systems of the helmet, such as improved cooperation with visor assemblies including a breathguard, or ventilation systems having conduits defined in the liner and/or through the helmet shell, for example.

The present disclosure may be embodied in other specific forms without departing from the subject matter of the claims. The described example embodiments are to be considered in all respects as being only illustrative and not restrictive. For example, in the embodiments described herein, the lateral liner portions include disconnected/independent left and right liner portions. However, in alternate embodiments, the lateral liner portion can be formed as a single unit, where the left liner portion is connected to the right liner portion, such as via a connecting liner portion adapted to extend between the left and right liner portions (e.g., around a neck and/or the back of the head of the wearer).

The present disclosure intends to cover and embrace all suitable changes in technology. The scope of the present disclosure is, therefore, described by the appended claims rather than by the foregoing description. The scope of the claims should not be limited by the embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.

As used herein, the terms “coupled”, “coupling”, “attached”, “connected” or variants thereof as used herein can have several different meanings depending in the context in which these terms are used. For example, the terms coupled, coupling, connected or attached can have a mechanical connotation. For example, as used herein, the terms coupled, coupling or attached can indicate that two elements or devices are directly connected to one another or connected to one another through one or more intermediate elements or devices via a mechanical element depending on the particular context.

In the present disclosure, an embodiment is an example or implementation of the described features. The various appearances of “one embodiment,” “an embodiment” or “some embodiments” do not necessarily all refer to the same embodiments. Although various features may be described in the context of a single embodiment, the features may also be provided separately or in any suitable combination. Conversely, although the helmet and/or the liner assembly may be described herein in the context of separate embodiments for clarity, it may also be embodied in a single embodiment. Reference in the specification to “some embodiments”, “an embodiment”, “one embodiment”, or “other embodiments”, means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least some embodiments, but not necessarily in all embodiments.

In the above description, the same numerical references refer to similar elements. Furthermore, for the sake of simplicity and clarity, namely so as to not unduly burden the figures with several references numbers, not all figures contain references to all the components and features, and references to some components and features may be found in only one figure, and components and features of the present disclosure which are illustrated in other figures can be easily inferred therefrom. The embodiments, geometrical configurations, materials mentioned and/or dimensions shown in the figures are optional, and are given for exemplification purposes only.

In addition, although the optional configurations as illustrated in the accompanying drawings include various components and although the optional configurations of the helmet as shown may consist of certain geometrical configurations as explained and illustrated herein, not all of these components and geometries are essential and thus should not be taken in their restrictive sense, i.e., should not be taken as to limit the scope of the present disclosure. It is to be understood that other suitable components and cooperation thereinbetween, as well as other suitable geometrical configurations may be used for the embodiment and use of the helmet, and corresponding parts, as briefly explained and as can be easily inferred herefrom, without departing from the scope of the disclosure.

Claims

1. A helmet comprising: a helmet shell having an inner surface defining a cavity and a frontal opening;a liner assembly for engagement with the helmet shell within the cavity, the liner assembly comprising: a lateral liner portion comprising a left liner portion and a right liner portion, each of the left and right liner portions having an outer surface complementarily shaped relative to left and right inner surface portions of the inner surface, respectively, and configured to engage with same, where the left liner portion includes a left chin segment, and the right liner portion includes a right chin segment, the left and right chin segments being configured to engage one another proximate a front section of the helmet shell; anda central liner portion engageable between the left and right liner portions and having an outer surface complementarily shaped relative to a central inner surface portion for engagement therewith.

2. The helmet of claim 1, wherein the complementarily shaped outer surfaces of the left and right liner portions and the left and right inner surface portions are adapted to engage one another to at least partially reduce relative movement between the left and right liner portions and the helmet shell.

3. The helmet of claim 1, wherein the central liner portion comprises central engagement surfaces provided on either side thereof, and wherein the left and right liner portions include respective lateral engagement surfaces configured to engage with the central engagement surfaces.

4. The helmet of claim 3, wherein each central engagement surface comprises one or more projections extending therefrom, and wherein each lateral engagement surface comprises one or more recesses adapted to receive respective projections therein, the projections and recesses being adapted to cooperate to at least partially reduce relative movement between the central liner portion and the left and right liner portions.

5. The helmet of claim 3, wherein the central engagement surfaces are shaped and sized to bias the left and right liner portions outwardly and away from the central liner portion upon engagement of the central liner portion between the left and right liner portions.

6. The helmet of claim 1, wherein the central liner portion comprises rabbeted edges extending along left and right sides thereof.

7. The helmet of claim 6, wherein each rabbeted edge comprises at least one angled surface configured to bias the left and right liner portions outwardly and away from the central liner portion upon engagement of the central liner portion between the left and right liner portions.

8. The helmet of claim 6, wherein the left and right liner portions each include an overhang adapted to engage respective rabbeted edges and define rabbet joints therewith.

9. The helmet of claim 1, further comprising a bottom opening, and wherein the central liner portion extends from a rear section of the helmet shell proximate the bottom opening, along the central inner surface portion and to the front section proximate the frontal opening.

10. The helmet of claim 1, wherein the central liner portion comprises a frontal segment adapted to be spaced from the inner surface of the helmet shell, thereby defining a gap therebetween.

11. The helmet of claim 10, wherein the left and right liner portions comprise respective forward segments adapted to be spaced from the inner surface of the helmet shell, and wherein the gap is further defined between the inner surface of the helmet shell and the forward segments.

12. The helmet of claim 1, further comprising a chin guard provided at the front section of the helmet shell and at least partially defining a periphery of the frontal opening, and wherein the left and right chin segments extend along the chin guard on respective sides thereof and engage one another substantially at a middle point of the chin guard.

13. The helmet of claim 1, wherein each one of the left and right chin segments includes an engagement surface adapted to engage the engagement surface of the other one of the left and right chin segments.

14. The helmet of claim 13, wherein one of the engagement surfaces comprises a protrusion, and wherein another one of the engagement surfaces comprises a recess adapted to receive the protrusion therein when the engagement surfaces engage one another.

15. The helmet of claim 1, wherein each one of the left liner portion, the right liner portion and the central liner portion is made of a single piece.

16. The helmet of claim 1, further comprising a chin brace coupled to the left and right chin segments and extending along the periphery of the frontal opening to reinforce the left and right chin segments within the cavity.

17. A helmet liner assembly for installation within a cavity of a helmet shell along an inner surface thereof, the helmet liner assembly comprising: a lateral liner portion comprising a left liner portion and a right liner portion, each of the left and right liner portions having an outer surface complementarily shaped relative to left and right inner surface portions of the inner surface, respectively, and configured to engage with same, where the left liner portion includes a left chin segment, and the right liner portion includes a right chin segment, the left and right chin segments being configured to engage one another proximate a front section of the helmet shell; anda central liner portion engageable between the left and right liner portions and having an outer surface complementarily shaped relative to a central inner surface portion for engagement therewith.

18. A method of installing a helmet liner assembly as defined in claim 17 within a helmet shell, comprising: inserting the left liner portion within the cavity for engagement with the left inner surface portion;inserting the right liner portion within the cavity for engagement with the right inner surface portion; andinserting the central liner portion within the cavity between the left and right liner portions for engagement therewith.

19. The method of claim 18, wherein the steps of inserting the left liner portion and the right liner portion within the cavity are done generally simultaneously.

20. A method of installing a helmet liner assembly within a helmet shell, comprising: inserting a left liner portion made of a single piece of material within a cavity of the helmet shell for engagement with a left inner surface portion thereof;inserting a right liner portion made of a single piece of material within the cavity for engagement with a right inner surface portion thereof; andinserting a central liner portion made of a single piece within the cavity between the left and right liner portions for engagement therewith, the central liner portion being configured to bias the left and right liner portions against corresponding inner surface portions of the helmet shell when engaged between the left and right liner portions.