FIELD AND BACKGROUND OF THE INVENTION
The subject technology relates to a protective helmet for sports play, such as a football helmet, hockey helmet, lacrosse helmet, or the like. The subject technology is suitable for use in full-contact sports, such as football, hockey, and lacrosse.
SUMMARY OF THE INVENTION
According to the subject technology, a helmet, such as a football helmet comprises a durable shell formed of a suitable material such as polycarbonate or acrylonitrile butadiene styrene plastic, adapted to receive and protect the head of a wearer. The helmet includes a shock-absorbing system including removable liner components attached to the inner surface of the shell; additionally, shock-absorbing elements are associated with the outer surface of the shell. In an embodiment of the subject technology, recesses are formed in the outer surface of the shell to receive shock-absorbing elements. Floating shell plates are provided over the shock-absorbing elements. In an embodiment of the subject technology, a crown recess contains a shock-absorbing cushion or sheet of thermoplastic polyurethane (TPU) material in which shock-absorbing elements are formed by molding. A floating shell plate is removably secured in contact with the peaks of the shock-absorbing elements. The floating shell plate has integral tabs formed therein which engages with niches or slots formed in the outer shell and associated with the crown recess. The floating shell plate is movable independently of the helmet shell in in a direction normal to the surface of the shell, and may be movable in a direction tangential to the helmet shell and in the normal and tangential directions in combination. A rear recess with its corresponding shock-absorbing TPU sheet and floating shell plate of similar construction is also provided.
Additionally, the subject technology is directed to a helmet liner system having relatively rigid shock absorbing elements attached to an inner surface of the shell, inflatable liner elements in contact with the wearer's head, and mobility layers interposed between the shock absorbing elements and inflatable liner elements. The mobility layers allow the inflatable liner elements to slip relative to the shock absorbing elements and have some degree of motion independent of the shock absorbing elements which are connected to the shell. Thus, when the helmet is subjected to a blow or force during sports play, acceleration of the shell is not entirely transmitted to the wearer's head.
Additionally, the subject technology is directed to a hybrid inner padding assembly for a helmet, including a helmet for a full-contact sport, such as football, comprising a molded TPU shock absorber having frustoconical projections extending from a base sheet, mated with a pad of molded foam material, the frustoconical projections being received snugly into openings formed in the pad of molded foam material.
BRIEF DESCRIPTION OF THE DRAWINGS
The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
FIG. 1 is a left, top, perspective view of a football helmet shell according to the subject technology.
FIG. 2 is a front elevational view of a football helmet shell according to the subject technology.
FIG. 3 is a rear elevational view of a football helmet shell according to the subject technology.
FIG. 4 is a right side elevational view of a football helmet shell according to the subject technology.
FIG. 5 is a left side elevational view of a football helmet shell according to the subject technology.
FIG. 6 is a top plan view of a football helmet shell according to the subject technology.
FIG. 7 is a bottom plan view of a football helmet shell according to the subject technology.
FIG. 8 is a plan view of a helmet according to the subject technology with floating shell plate removed showing shell cushions installed to the helmet.
FIG. 9 is a plan view of a helmet according to the subject technology.
FIG. 10 is a front view of a partially-assembled helmet according to the subject technology.
FIG. 11 is a rear view of a helmet according to the subject technology.
FIG. 12 is a left side view of a helmet according to the subject technology.
FIG. 13 is a bottom view of a partially assembled helmet according to the subject technology.
FIG. 14 is a sectional view of a partially assembled helmet according to the subject technology.
FIG. 15 is a partially exploded view of the crown area of a helmet according to the subject technology.
FIG. 16 is a rear perspective view of shock absorbing elements disposed on the inner surface of a helmet according to the subject technology.
FIG. 17 is a plan view of a floating shell plate according to the subject technology.
FIG. 18 is a side view of a floating shell plate according to the subject technology.
FIG. 19 is a cross-section view of a floating shell plate according to the subject technology.
FIG. 20 is a perspective view of a floating shell plate according to the subject technology.
FIG. 21 is a plan view of a floating shell plate according to the subject technology.
FIG. 22 is a cross-section view of a floating shell plate according to the subject technology.
FIG. 23 is a plan view of a shell cushion according to the subject technology.
FIG. 24 is a cross-section view of a shell cushion according to the subject technology.
FIG. 25 is a perspective view of a shell cushion according to the subject technology.
FIG. 26 is a perspective view of a shell cushion according to the subject technology.
FIG. 27 is a plan view of a shell cushion according to the subject technology.
FIG. 28 is a detail view of ridges of the shell cushion of FIG. 27 according to the subject technology.
FIG. 29 is a perspective view of a front area shock absorbing element according to the subject technology.
FIG. 30 is a bottom view of a front area shock absorbing element according to the subject technology.
FIG. 31 is a cross-sectional view of a front area shock absorbing element according to the subject technology.
FIG. 32 is a top view of a front area shock absorbing element according to the subject technology.
FIG. 33 is a rear view of a front pad according to the subject technology.
FIG. 34 is a cross-sectional view of a front pad according to the subject technology.
FIG. 35 is a perspective view of a front pad according to the subject technology.
FIG. 36 is a rear view of a front pad assembly according to the subject technology.
FIG. 37 is a front view of a front pad assembly according to the subject technology.
FIG. 38 is a front view of a front pad assembly according to the subject technology, inside the comfort layer fabric.
FIG. 39 is a rear view of a front pad assembly according to the subject technology, inside the comfort layer fabric.
FIG. 40 is a rear view of a lateral assembly of shock absorbing elements according to the subject technology.
FIG. 41 is a rear view of a central element of a lateral assembly of shock absorbing elements according to the subject technology.
FIG. 42 is a cross-sectional view of a central element of a lateral assembly of shock absorbing elements according to the subject technology.
FIG. 43 is a right side view of a central element of a lateral assembly of shock absorbing elements according to the subject technology.
FIG. 44 is a rear view of a top element of a lateral assembly of shock absorbing elements according to the subject technology.
FIG. 45 is a cross-sectional view of a top element of a lateral assembly of shock absorbing elements according to the subject technology.
FIG. 46 is a left side view of a left wing of a lateral assembly of shock absorbing elements according to the subject technology.
FIG. 47 is a rear view of a left wing of a lateral assembly of shock absorbing elements according to the subject technology.
FIG. 48 is a cross-sectional view of a left wing of a lateral assembly of shock absorbing elements according to the subject technology.
FIG. 49 is a rear view of a right wing of a lateral assembly of shock absorbing elements according to the subject technology.
FIG. 50 is a cross-sectional view of a right wing of a lateral assembly of shock absorbing elements according to the subject technology.
FIG. 51 is a right side view of a right wing of a lateral assembly of shock absorbing elements according to the subject technology.
FIG. 52 is a rear view of a lateral mobility layer according to the subject technology.
FIG. 53 is a side view of a lateral mobility layer according to the subject technology.
FIG. 54 is a front view of a lateral mobility layer according to the subject technology.
FIG. 55 is a perspective view of an inflatable lateral liner according to the subject technology.
FIG. 56 is a front view of an inflatable lateral liner according to the subject technology.
FIG. 57 is a rear view of an inflatable lateral liner according to the subject technology.
FIG. 58 is a side view of an inflatable lateral liner according to the subject technology.
FIG. 59 is a detail view of an inflatable cell of an inflatable lateral liner according to the subject technology.
FIG. 60 is a cross sectional view of an inflatable lateral liner according to the subject technology.
FIG. 61 is a front view of the assembly of a lateral mobility layer to an inflatable lateral liner according to the subject technology.
FIG. 62 is a side view of the assembly of a lateral mobility layer to an inflatable lateral liner according to the subject technology.
FIG. 63 is a plan view of the assembly of the lateral TPU assembly, lateral mobility layer, and inflatable lateral liner of the subject technology.
FIG. 64 is a plan view of the assembly of the lateral TPU assembly, lateral mobility layer, and inflatable lateral liner of the subject technology.
FIG. 65 is a detail view of the assembly of the lateral TPU assembly, lateral mobility layer, and inflatable lateral liner of the subject technology.
FIG. 66 is a detail view of the assembly of the lateral TPU assembly, lateral mobility layer, and inflatable lateral liner of the subject technology, showing how the valve assembly of the inflatable lateral liner is assembled through the keyway in the lateral TPU assembly.
FIG. 67 is a perspective view of a crown shock absorbing element according to the subject technology.
FIG. 68 is a bottom view of a crown shock absorbing element according to the subject technology.
FIG. 69 is a cross-sectional view of a crown shock absorbing element according to the subject technology.
FIG. 70 is a top view of a crown shock absorbing element according to the subject technology.
FIG. 71 is a front view of a crown mobility layer according to the subject technology.
FIG. 72 is a rear view of a crown mobility layer according to the subject technology.
FIG. 73 is a side view of a crown mobility layer according to the subject technology.
FIG. 74 is a front view of a crown lateral liner according to the subject technology.
FIG. 75 is a cross-sectional view of a crown lateral liner according to the subject technology.
FIG. 76 is a perspective view of the assembly of a crown inflatable element, crown mobility layer, and crown shock absorbing element according to the subject technology.
FIG. 77 is a perspective view of the assembly of a crown inflatable element, crown mobility layer, and crown shock absorbing element according to the subject technology.
FIG. 78 is a top view of a face guard twist-release mount according to the subject technology.
FIG. 79 is a cross-sectional view of a face guard twist-release mount according to the subject technology.
FIG. 80 is a front view of a face guard twist-release mount according to the subject technology.
FIG. 81 is a cross-sectional view of a face guard twist-release mount according to the subject technology.
FIG. 82 is a rear view of a face guard twist-release mount according to the subject technology.
FIG. 83 is a right side view of a right outer brace for a cheek support according to the subject technology.
FIG. 84 is a left side view of a right outer brace for a cheek support according to the subject technology.
FIG. 85 is a front view of a right outer brace for a cheek support according to the subject technology.
FIG. 86 is a cross-sectional view of a right outer brace for a cheek support according to the subject technology.
FIG. 87 is a right side view of a left outer brace for a cheek support according to the subject technology.
FIG. 88 is a left side view of a left outer brace for a cheek support according to the subject technology.
FIG. 89 is a front view of a left outer brace for a cheek support according to the subject technology.
FIG. 90 is a cross-sectional view of a left outer brace for a cheek support according to the subject technology.
FIG. 91 is a view of the outer face of an inner plate for a right cheek support
FIG. 92 is a view of the inner face of an inner plate for a right cheek support
FIG. 93 is a view of the outer face of an inner plate for a left cheek support
FIG. 94 is a view of the inner face of an inner plate for a left cheek support
FIG. 95 is a plan view of a left side cheek pad for a cheek support according to the subject technology.
FIG. 96 is a bottom view of a left side cheek pad for a cheek support according to the subject technology.
FIG. 97 is a plan view of a right side cheek pad for a cheek support according to the subject technology.
FIG. 98 is a bottom view of a right side cheek pad for a cheek support according to the subject technology.
FIG. 99 is a plan view of a pad of resilient polymer foam material which may be disposed in the inflatable cells of the inflatable liners according to the subject technology.
FIG. 100 is a plan view of a pad of resilient polymer foam material which may be disposed in the inflatable cells of the inflatable liners according to the subject technology.
FIG. 101 is a plan view of a pad of resilient polymer foam material which may be disposed in the inflatable cells of the inflatable liners according to the subject technology.
FIG. 102 is a top view of a shock absorbing element having a dense distribution of cones according to the subject technology.
FIG. 103 is a side view of a shock absorbing element having a dense distribution of cones according to the subject technology.
FIG. 104 is a cross-sectional view of a shock absorbing element having a dense distribution of cones according to the subject technology.
FIG. 105 is a front view of a face guard for attachment to a helmet according to the subject technology.
FIG. 106 is a left side view of a face guard for attachment to a helmet according to the subject technology.
FIG. 107 is a front view of a face guard for attachment to a helmet according to the subject technology.
FIG. 108 is a left side view of a face guard for attachment to a helmet according to the subject technology.
FIG. 109 is a front view of a face guard for attachment to a helmet according to the subject technology.
FIG. 110 is a left side view of a face guard for attachment to a helmet according to the subject technology.
FIG. 111 is a front view of a face guard for attachment to a helmet according to the subject technology.
FIG. 112 is a left side view of a face guard for attachment to a helmet according to the subject technology.
FIG. 113 is a front view of a face guard for attachment to a helmet according to the subject technology.
FIG. 114 is a left side view of a face guard for attachment to a helmet according to the subject technology.
FIG. 115 is a front view of a face guard for attachment to a helmet according to the subject technology.
FIG. 116 is a left side view of a face guard for attachment to a helmet according to the subject technology.
FIG. 117 is a front view of a face guard for attachment to a helmet according to the subject technology.
FIG. 118 is a left side view of a face guard for attachment to a helmet according to the subject technology.
FIG. 119 is a front view of a face guard for attachment to a helmet according to the subject technology.
FIG. 120 is a left side view of a face guard for attachment to a helmet according to the subject technology.
FIG. 121 is a front view of a face guard for attachment to a helmet according to the subject technology.
FIG. 122 is a left side view of a face guard for attachment to a helmet according to the subject technology.
FIG. 123 is a front view of a face guard for attachment to a helmet according to the subject technology.
FIG. 124 is a left side view of a face guard for attachment to a helmet according to the subject technology.
FIG. 125 is a front view of a face guard for attachment to a helmet according to the subject technology.
FIG. 126 is a left side view of a face guard for attachment to a helmet according to the subject technology.
FIG. 127 is a front view of a face guard for attachment to a helmet according to the subject technology.
FIG. 128 is a left side view of a face guard for attachment to a helmet according to the subject technology.
DETAILED DESCRIPTION OF THE DRAWINGS
As shown for example in FIGS. 1-6, helmet 1 shell according to the subject technology comprises a shell 10 composed of a suitable material such as polycarbonate, reinforced fiberglass, carbon fiber composite, or acrylonitrile butadiene styrene (ABS) plastic. Preferably the material of shell 10 is strong enough to resist impacts but retaining some flexibility. Shell 10 may be manufactured by means known to those of skill in the art including thermoplastic injection molding and thermoforming. Shell 10 has bilateral symmetry about a plane of symmetry P bisecting shell 10. Shell 10 has a front area, left area, right area, and rear area. Shell 10 has a front edge 29, left edge 30, right edge 31, and bottom edge 32. Edges 29-31 define a face opening of shell 10. Left and right edges 30 and 31 meet bottom edge 32 at curved transitions to define a left earflap 33 and right earflap 34 of a conventional type, size and extent known to the art, in the left area and right area respectively. Shell 10 may be formed as two molded hemispheres, particularly a left hemisphere and a right hemisphere which are joined together along the plane of symmetry P.
Notable features of shell 10 according to the subject technology are recesses formed in the shell, which according to an embodiment are lying in and bisected by plane of symmetry P, which are adapted to contain shock absorbing elements covered by floating shell plates, as hereinafter described.
Crown recess 12 is formed in shell 10 for receiving crown shock absorbing pad or cushion 70 and crown floating shell plate 60 as hereinafter described. Crown recess 12 has floor 14 defined by front bank 15, rear bank 16, left bank 17, right bank 18. Banks 15-18 are preferably formed to slope at an obtuse angle from the outer surface of the surrounding shell 10 to floor 14. Alternatively, banks 15-18 are formed to slope at a right angle, or approximately a right angle. Each of banks 15-18 may have formed therein one more niches or through-going slots. In the embodiment of FIGS. 1-6, front bank 15 has two through-going slots 19 and rear bank 16 has two through-going slots 20. Preferably, crown recess 12 is bisected by plane P and has bilateral symmetry about plane P.
Rear recess 21 is formed in shell 10 for receiving rear shock absorbing pad 90 and crown floating shell plate 80 as hereinafter described. Rear recess 21 has floor 22 defined by front bank 23, rear bank 24, left bank 25, right bank 26. Banks 23-26 are preferably formed to slope at an obtuse angle from the outer surface of the surrounding shell 10 to floor 22. Alternatively, banks 23-26 are formed to slope at a right angle, or approximately a right angle. Each of banks 23-26 may have formed therein one more niches or through-going slots. In the embodiment of FIGS. 1-6, front bank 23 has two through-going slots 27 and rear bank 24 has two through-going slots 28. Preferably, rear recess 12 is bisected by plane P and has bilateral symmetry about plane P.
In the embodiments of FIGS. 1-6, crown recess 12 is longer than rear recess 21 and has the same width as rear recess 21. Alternatively, crown recess 12 is wider than rear recess 21. Alternatively, crown recess 12 is narrower than rear recess 21. Alternatively, crown recess 12 has the same length as rear recess 21. Alternatively, rear recess 21 is longer than crown recess 12.
Outside of recesses 12 and 21, shell 10 is divided into zones of unequal elevation delimited from and connected to neighboring zones by sloped banks.
A first zone 100 of highest elevation includes a forehead region 35 which is rectangular, roughly rectangular, or trapezoidal, and sweeping region 39.
In the embodiment of FIGS. 1-6, forehead region 35 extends from front edge 29 toward crown recess 12 and is partially defined by banks 36, 37, 38. Bank 38 slopes toward and abuts front bank 15 of crown recess 12. The top edge of forehead region 35 may be the same width as floor 14. Forehead region 35 may broaden from bank 38 in the direction of front edge 29.
First zone 100 extends from forehead region 35 along front edge 29 and forms sweeping region 39 which sweeps across the shell from left edge 30 to right edge 31. Rear recess 21 is located in sweeping region 39 of first zone 100. Sweeping region 39 can be viewed as consisting of a right temporal wing 101 and a left temporal wing 102, with rear recess 21 located in the rear of the helmet where right temporal wing 101 and left temporal wing 102 meet. Right temporal wing 101 begins at the right edge 31 of shell 10 and sweeps across the right side of shell 10 above earholes 48, 49 associated with the right earflap 34 toward rear recess 21. Left temporal wing 102 begins at the left edge 30 of shell 10 and sweeps across the left side of shell 10 above earholes 48, 49 associated with the left earflap 33 toward rear recess 21. First zone 100, forehead region 35, sweeping region 39, right temporal wing 101 and left temporal wing 102 strengthen shell 10 by imparting additional resistance to flexing, and thereby improve the strength and durability of the helmet.
First zone 100 may include provisions for attaching loopstraps to shell 10. The provisions may include recesses 103 formed in first zone 100 in which holes may be formed for mounting loopstraps to shell 10 by means of screws and T-nuts.
A second zone 110 of lower elevation than first zone 100 is partially surrounded by first zone 100. Crown recess 12 is located in second zone 110. Crown recess 12 may be oriented lengthwise along the plane P and extend from the edge of first zone 100 and/or forehead region 35 to the edge of first zone 100, or the edge of second zone 10, or more particularly the border between first zone 100 and second zone 100. Second zone 110 rises to meet first zone 100 at points adjacent to rear bank 16 of crown recess 12. Second zone 110 may have through-going holes or slots for ventilation. In the embodiment shown in FIGS. 1-6, second zone 110 has elongated ventilation slots 44, 45 alongside banks 40, 41, respectively, in the right area of the helmet, and elongated ventilation slots 46, 47 alongside banks 42, 43, respectively, in the left area of the helmet. Ventilation slots 44, 45 are not co-linear, and define between them an angle greater than 90 degrees. Similarly, ventilation slots 46, 47 are not co-linear, and define between them an angle greater than 90 degrees.
A third zone 120 of lower elevation than first zone 100 is adjacent to sweeping region 39 of first zone 100. Third zone 120 is joined to sweeping region 39 by bank 11, and is joined to fourth zone 130 by bank 13. Third zone 120 sweeps across the shell from left earflap 33 to right earflap 34. Third zone 120 may have one or more through-going ear holes associated with the left earflap 33 and right earflap 34. In the embodiment of FIGS. 1-6, each earflap is associated with two earholes, specifically, a convex earhole 48 and a concave earhole 49. Raised rear area, or back shelf, 50 in third zone 120 is bounded on the left edge and right edge by banks sloping down to third zone 120; bounded on the top by the bank 11 sloping down from sweeping region 39 of first zone 100 to third zone 120; and bounded on the bottom by the bank 13 sloping down from third zone 120 to fourth zone 130. Raised rear area, or back shelf, 50 imparts greater flexural resistance to shell 10. Through-going elongated ventilation slots 58 may be formed in raised rear area 50. Through-going elongated ventilation slots 59 may be formed in third zone 120.
A fourth zone 130 of lowest elevation than third zone 120 is adjacent to third zone 120. Fourth zone 130 is bounded by bottom edge 32 and sweeps across shell 10 from left earflap 33 to right earflap 34.
Turning now to the shock absorbers and floating shell plates disposed in shell recesses, as shown for example in FIGS. 17-19, a floating shell plate 50 for crown recess 12 according to an embodiment of the subject technology is composed of a single sheet of material suitable for use in a helmet shell, for example, ABS, polycarbonate, reinforced fiberglass, or carbon fiber composite. Floating shell plate 50 may be manufactured by injection molding or thermoforming. Floating shell plate 50 is sized and shaped to serve as a lid or cover over crown recess 12. Floating shell plate 50 has a body 51 and tabs extending from body 51 at the periphery of body 51. In an embodiment of the present technology, floating shell plate has two tabs 52 positioned at a top edge of body 51 and two tabs 53 positioned on the opposite (bottom) edge of the body 51. Body 51 is curved to conform to the outer curvature of the profile of second zone 100 shell 10. Tabs 52, 53 are sized and adapted to engage with niches or slots 19, 20 in the walls of crown recess 12. Accordingly, tabs 52, 53 extend downwardly at an angle from the periphery of body and each tab may terminate in a bent end which is adapted to be inserted into slots 19, 20 in the walls of crown recess 12, thereby removably retaining the floating shell plate over crown recess 12. Alternatively, each tab 52, 53 may terminate in a straight end. Left and right edges of body 51 may be formed with a plurality of segments 54 connected by angled transition portions 55 to form crenulations or crenulated edges along the left and right of body 51. To further secure the connection of floating shell plate 50 to shell 10, the body 51 may be provided with through-going holes 56 for receiving a screw or bolt connecting plate 50 to cushion 70, or to shell 10, or to both. Floating shell plate 50 may have a thickness of 0.090 inches or approximately 0.090 inches. Floating shell plate 50 may have one or more holes 56 or elongated slots 57 formed therein.
As shown for example in FIGS. 27-28, a shock absorbing cushion 70 for crown recess 12 according to an embodiment of the subject technology is composed of a single flexible sheet of TPU material by molding or thermoforming. According to an embodiment of the subject technology, cushion 70 is sized and adapted to nest and fit closely within crown recess 12 of the shell.
Domes are formed in a base sheet 73 of TPU material and are distributed over a coverage area to provide shock absorption between floor 14 and floating shell plate 50. Base sheet 73 is formed in a curved shape to match the curvature of floor 14. Domes may be oriented outwardly (i.e. in the direction away from floor 14), or inwardly (toward floor 14, thereby forming cups). In an embodiment of the subject technology, rows 74 of aligned, alternating domes 71 and cups 72 are formed in base sheet 73 (only one such row is numbered in the figures). Preferably, the sequence of domes and cups in a row is the inverse of the sequence in the neighboring row. Other arrangements of domes and/or cups in base sheet 73 is within the scope of the subject technology, for example, all domes, all cups, rows of cups alternating with adjacent rows of domes. Holes 75 may be formed in the base sheet 73 for attachment of cushion 70 to shell 10. The holes 75 may be defined and surrounded by a thickened area 76 to strengthen the part. Holes 76 may be formed in the base sheet 73 for attachment of plate 50 to cushion 70, or to shell 10, or both. Holes 75, 76 may be defined and surrounded by a thickened area to strengthen the part. The edges of the cushion 70 may be formed as thickened ridges 80, 81 interrupted by cutouts. In an embodiment of the subject technology, four cutouts 78, 79 are formed in the ridges, two cutouts 78 on a top edge of the pad and two cutouts 79 on the opposite, bottom edge. Cutouts 78, 79 coincide with tabs 52, 53 to permit tabs 52, 53 to engage with niches or slots 19, 20, respectively. In an embodiment of the subject technology, four ridges 80,81 are formed at the edges of base sheet 73. Preferably, ridges 80,81 are sized so as not to protrude above the surface defined by plate 50. Ridges 80 at the top edge and bottom edge of base sheet 73 may be formed with a triangular cross-section, the peak 82 of the triangle at the point of contact between ridges 80 and base sheet 73, the base 83 of the triangle oriented away from base sheet 73 and floor 14. In that embodiment, one side 84 of the triangle is formed to conform with the slope of the adjacent bank 15 or 16 so that when cushion 70 assembled to crown recess 12, side 84 closely contacts bank 15 or 16. Additionally, base 83 may be formed to conform with the curvature of floating shell plate 50 so that the curvature is smoothly continued from plate 50 over base 83. Preferably, the length of ridges 80 is less than the distance between tabs 52, 53, to define a gap between the left and right ends of ridges 80 and the inner edges of tabs 52, 53, so that floating shell plate 50 is permitted to move in a direction tangential to the surface of shell 10.
As best seen in FIG. 8, cushion 70 is assembled to crown recess 12 so that the peaks of any cups 72 are contacting floor 14 and base sheet 73 is mostly suspended above floor 14, although base sheet 73 may contact floor 14 at points where it is not supported by adjacent cups 72. In an embodiment in which cushion 70 has no cups and only domes, base sheet 73 is contacting floor 14. Cushion 70 may be removably secured to shell 10 by screws and T-nuts passing through holes 75 and corresponding holes in floor 14. Cutouts 78, 79 align with niches or slots 19, 20 so that cushion 70 and base sheet 73 are not obstructing niches or slots 19, 20. As best seen in FIG. 9, crown floating shell plate 50 is assembled over cushion 70. Tabs 52, 53 are inserted into niches or slots 19, 20 via cutouts 78, 79 in cushion 70. The crenulations, holes 56 and/or elongated slots 57 may expose portions of cushion 70. Floating shell plate 50 is removably attached by a screw or bolt passing through holes 56 connecting plate 50 to cushion 70, or to shell 10, or to both. In an embodiment in which floating shell plate 50 is removably attached to cushion 70 but not to shell 10, advantageously, a relatively large hole may be formed in floor 14 below the hardware (screw or bolt) connecting plate 50 to cushion 70, so that the hardware is not normally contacting floor 14.
Rear recess 21 receives shock absorbing cushion 90 and floating shell plate 60, which are similar in form and function to shock absorbing cushion 70 and floating shell plate 50, respectively. As shown for example in FIGS. 20-22, a floating shell plate 60 for rear recess 21 according to an embodiment of the subject technology is composed of a single sheet of polymer material suitable for use in a helmet shell, for example, ABS, polycarbonate, reinforced fiberglass, or carbon fiber composite. The floating shell plate 60 may be formed by injection molding or thermoforming. Floating shell plate 60 has a body 61 and tabs 62, 63 extending from the body 61 at the periphery of the body. Floating shell plate 60 is sized and shaped to serve as a lid or cover over rear recess 21. In an embodiment of the present technology, floating shell plate has two tabs 62 positioned at a top edge of the body and two tabs 63 positioned on the opposite, bottom, edge of the body. Body 61 is curved to conform to, and continue, the outer curvature of the shell profile of sweeping region 39 of first zone 100. Tabs 63, 63 are sized and adapted to engage with the niches or slots 27, 28 in the walls of the rear recess 21. Accordingly, tabs 61, 62 extend downwardly at an angle from the periphery of body and each tab may terminate in a bent end which is adapted to be inserted into the slots 27, 28 in the banks of the rear recess 21, thereby removably retaining floating shell plate 60 in rear recess 21. Alternatively, each tab 62, 63 may terminate in a straight end. Left and right edges of body 61 may be formed with segments 64 connected by angled transition portion 65. To further secure the connection of floating shell plate 60 to shell 10, the body 61 may be provided with through-going hole 66 for receiving a screw or bolt connecting plate 60 to cushion 90, or to shell 10, or to both. One or more slots 67 may be formed in body 61. Floating shell plate 60 may have a thickness of 0.090 inches or approximately 0.090 inches. Floating shell plate 60 may have one or more hole(s) 66 or elongated slots 67 formed therein.
As shown for example in FIGS. 23-26, a shock absorbing cushion 90 for rear recess 21 according to an embodiment of the subject technology is composed of a single flexible sheet of TPU material by molding or thermoforming. According to an embodiment of the subject technology, cushion 90 is sized and adapted to nest and fit closely within rear recess 21 of the shell. Domes are formed in a base sheet 93 of TPU material and are distributed over a coverage area to provide shock absorption between floor 22 and floating shell plate 60. Base sheet 93 is formed in a curved shape to match the curvature of floor 22. Domes may be oriented outwardly (i.e. in the direction away from floor 22), or inwardly (toward floor 22, thereby forming cups). In an embodiment of the subject technology, a row 94 of aligned, alternating domes 91 and cups 92 is formed in the forward edge of base sheet 93. A second row 86 of domes is formed amid base sheet 93. A third row 87 of cups is formed in a rear edge of base sheet 93. Other arrangements of domes and/or cups in base sheet 93 is within the scope of the subject technology, for example, all domes, all cups, rows of cups alternating with adjacent rows of domes. Holes 95 may be formed in the base sheet 93 for attachment of cushion 90 to shell 10. The holes 95 may be defined and surrounded by a thickened area 76 to strengthen the part. Holes 89 may be formed in the base sheet 93 for attachment of plate 90 to cushion 90, or to shell 10, or both (more than one hole could be formed and used for this purpose). Holes 89, 95 may be defined and surrounded by a thickened area to strengthen the part. The edges of the cushion 90 may be formed as thickened ridges 96, 97 interrupted by cutouts. In an embodiment of the subject technology, four cutouts 98, 99 are formed in the ridges, two cutouts 98 on a top edge of the pad and two cutouts 99 on the opposite, bottom edge. Cutouts 98, 99 coincide with tabs 62, 63 to permit tabs 62, 63 to engage with niches or slots 27, 28, respectively. In an embodiment of the subject technology, four ridges 80,81 are formed at the edges of base sheet 93. Preferably, ridges 96, 97 are sized so as not to protrude above the surface defined by plate 60. Ridges 96 at the top edge and bottom edge of base sheet 93 may be formed with a triangular cross-section, the peak 103 of the triangle at the point of contact between ridges 96 and base sheet 93, the base 104 of the triangle oriented away from base sheet 93 and floor 22. In that embodiment, one side 105 of the triangle is formed to conform with the slope of the adjacent bank 23 or 24 so that when cushion 90 assembled to rear recess 21, side 105 closely contacts bank 23 or 24. Additionally, base 104 may be formed to conform and continue with the curvature of floating shell plate 60 so that the curvature is smoothly continued from plate 60 over base 104. Preferably, the length of ridges 96 is less than the distance between tabs 61, 62, to define a gap between the left and right ends of ridges 80 and the inner edges of tabs 61, 62, so that floating shell plate 50 is permitted to move in a direction tangential to the surface of shell 10. The ridges 97 on the left and right edges of cushion 90 may be formed with a relatively thick lower segment 106 connected to a relatively thin upper segment 107 by an angled transition portion, forming a shelf.
FIG. 8 in particular shows a helmet 1 according to the subject technology with the floating shell plates removed, to show the assembly of cushions 70, 90 to shell 10 in recesses 12, 21.
FIG. 14 shows a sectional rendering of shell 10, floating shell plates 50, 60, cushions 70, 90, with an inner plate for a cheek support attached to the right earflap.
FIG. 15 shows a partially exploded view of floating shell plates 50, 60 with respect to shell 10. Cushion 70 is shown as installed in crown recess 12.
In use in sports play, when helmet 1 is subjected to forces and blows on and around plate 50, a component of force normal (i.e. perpendicular) to the surface of plate 50 compresses one or more of domes 71 and/or cups 72, between plate 50 and floor 14, which compression is resiliently resisted by the TPU material of cushion 70, domes 71 and/or cups 72. And while the material of plate 50 is somewhat flexible, the curvature of body 51 of plate 50 gives it sufficient rigidity that the compressive normal force is distributed over a number of domes 71 and/or cups 72. A component of force tangential to the surface of plate 50 urges plate 50 to move in the direction of the force. In response to the tangential component of force (i.e., the component parallel to the surface of plate 50), plate 50 may move or slide, with consequent resilient deformation of cushion 70 and its base sheet 73 by the action of plate 50 and its connection to cushion 70.
After the force is removed, cushion 70 and its base sheet 73, domes 71 and/or cups 72 resiliently rebound and return to their original shape, and plate 50 is restored to its original position. In this way, plate 50 is resiliently movable independently of shell 10 when subjected to forceful blows, reacting in multiple directions to help better distribute the energy of an impact. In embodiments in which the length of ridges 80 is less than the distance between tabs 52, 53, to define a gap between the left and right ends of ridges 80 and the inner edges of tabs 52, 53, floating shell plate 50 has more freedom of movement in the lateral or tangential direction, which is advantageous for this mode of operation.
Similarly, when helmet 1 is subjected to forces and blows on and around plate 60, a component of force normal (i.e. perpendicular) to the surface of plate 60 compresses one or more of domes 91 and/or cups 92, between plate 60 and floor 22, which compression is resiliently resisted by the TPU material of cushion 90, domes 91 and/or cups 92. And while the material of plate 60 is somewhat flexible, the curvature of body 61 of plate 60 gives it sufficient rigidity that the compressive normal force is distributed over a number of domes 91 and/or cups 92. A component of force tangential to the surface of plate 60 urges plate 60 to move in the direction of the force. In response to the tangential component of force (i.e., the component parallel to the surface of plate 60), plate 60 may move or slide, with consequent resilient deformation of cushion 90 and its base sheet 93 by the action of plate 60 and its connection to cushion 90.
After the force is removed, cushion 90 and its base sheet 93, domes 91 and/or cups 92 resiliently rebound and return to their original shape, and plate 60 is restored to its original position. In this way, plate 60 is resiliently movable independently of shell 10 when subjected to forceful blows, reacting in multiple directions to help better distribute the energy of an impact. In embodiments in which the length of ridges 96 is less than the distance between tabs 62, 63, to define a gap between the left and right ends of ridges 96 and the inner edges of tabs 62, 63, floating shell plate 60 has more freedom of movement in the lateral or tangential direction, which is advantageous for this mode of operation.
Helmet 1 may have attached to shell 10 cheek supports, such as those disclosed in U.S. patent application Ser. No. 15/456,279, published as U.S. Patent Published Patent Application 2017/0291095, for “Football Helmet with Cheek Supports,” the entire disclosure of which is hereby incorporated by reference, which is assigned to the assignee of the present application. The disclosed cheek supports, which may also be used in the present technology of helmet 1, consist of an outer brace, an inner plate, and cheek pads associated with the inner plate, all of which are more particularly described in the incorporated pending patent application. FIGS. 83-90 show views of outer braces which may be used in helmet 1, as alternatives to the outer braces described in the incorporated pending patent application. FIGS. 91-94 show views of inner plates which may be used in helmet 1, as alternatives to the outer braces described in the incorporated pending patent application. FIGS. 95-98 show views of cheek pads which may be used in helmet 1, as alternatives to the outer braces described in the incorporated pending patent application. The function, materials, dimensions and structure of the outer brace, inner plate, cheek pads which may be used in helmet 1 are as described in the incorporated pending patent application. When helmet 1 is worn by a football player, as more particularly described in the incorporated pending patent application, the cheek pads are held firmly against the wearer's cheek to at least partially overlay the area of the zygomatic bone. The cheek pads exert forces bearing against the wearer's cheek area to help retain the helmet 1 on the head during sports play. The padding provided by the cheek pad also provides protection to that area against collisions.
Helmet 1 has inner padding elements removably attached to the inner surface of shell 10 to provide further shock absorption, to help better size the helmet to the wearer, and for the comfort of the wearer. Inner padding elements in helmet 1 include shock absorbing elements made of TPU consisting of a base sheet of TPU with projecting hollow cones, such as those described in U.S. Pat. No. 9,622,533 for “Single-layer padding system,” the entire disclosure of which is hereby incorporated by reference, which is assigned to the assignee of the present application. The TPU elements are installed in contact with the inner surface of shell 10.
FIGS. 67-70 show views of a TPU crown shock absorbing element that may be installed in the helmet 1 of the subject technology, in the crown area of helmet 1. According to the embodiment shown in FIGS. 67-70, crown TPU element 160 comprises a base sheet 161 having hollow frusto-conical projections 162 (only one is numbered) extending therefrom and distributed over the coverage area to provide shock absorption. Squared hollow cones 163 also provide shock absorption, and have T-nuts at their distal ends for attaching the assembly to the inner surface of shell 10. Projections 162 may have closed distal ends (i.e., the projections terminate in a surface which closes the upper end of the projections), alternatively, some or all of projections 162 may have open distal ends. In either case, the distal ends of projections 162 and 163 are slanted such that when installed, the distal ends overall conform to and closely contact the inner surface of shell 10. Crown TPU element 160 is curved overall to closely contact the inner surface of shell 10. Projections 162 and 163 may be each be connected to one or more of its neighbors by connecting ribs 164 (only one is numbered). Connecting ribs 164 stabilize element 160 by tending to support projections 162 and 163 and tending to prevent projections 162 and 163 from tipping or leaning when subjected to a shock or blow during sports play. Supported by ribs 164, projections 162 and 163 preferentially collapse in a resilient manner when subjected to shocks. Keyway 165 may be formed in base sheet 161 for passage of a tube for inflation of an inflatable liner component. Keyway 165 may be formed with retaining projections 166 to retain the inflation tube in keyway 165 during assembly, as hereinafter described in connection with the description of the crown inflatable liner.
FIGS. 29-32 show views of a TPU shock absorbing element, particularly a front pad insert, that may be installed in the helmet 1 of the subject technology, as hereinafter described.
FIGS. 29-32 show views of a TPU shock absorbing element which may be used in a front area of helmet 1, above the front edge 29 of the shell. This element may be used in conjunction with a front pad. FIGS. 34-35 show views of a front pad, which is made of a resilient polymer material such as EVA or slow-recovery EVA. The front pad includes recesses or through-going holes for receiving TPU cones of the front area TPU shock absorbing element, so that the element and pad may be assembled together to form a composite TPU/EVA front shock absorbing element. FIGS. 36-37 show views of the assembly of the element and pad. FIGS. 38-39 show views of the composite front pad, complete with its soft padded comfort layer.
As shown in FIGS. 29-32, TPU element 140 comprises a base sheet 141 having hollow frusto-conical projections extending therefrom to provide shock absorption. In the embodiment of this element as shown, element 140 comprises seven long cones 142 (only one is numbered), two short cones 143, and two squared cones 144. Squared cones 144 have T-nuts at their distal ends for attaching the assembly to the inner surface of shell 10.
Turning specifically to the EVA pad, as shown in FIGS. 33-35, pad 145 has a thick region 149 integrally formed with a thin region 150, thereby a recess 146 is formed therebetween. Thin region 150 has formed therein passages or holes 147 (only one is numbered) for receiving long cones 142. Passages 147 may pass all the way through thin region 150. Square holes 148 are formed in thin region 150 for receiving squared cones 144. Thick region 149 may have passages or holes 151 (only one is numbered) to improve the resiliency of that region; in an alternative embodiment, thick region 149 is formed without holes to result in a stiffer pad. Passages 147 may be sized to provide a friction or interference fit with long cones 142 such that long cones 142 fit snugly within passages 147. Pad 145 may be made of slow-recovery EVA having a hardness of 50 Shore “C”, or other foam or cushioning material suitable for the desired application. Pad 145 is molded to have a contoured outer surface 152 that nests within the inner surface of shell 10.
As shown in FIGS. 36-37, element 140 and pad 145 are assembled to form front pad assembly 153. TPU element 140 is received in recess 146, long cones 142 are received in passages 147, and the flat ends of short cones 143 abut the surface of thin region 150. As best seen in FIG. 37, in a preferred embodiment, long cones 142 extend through passages 147 such that the flat ends of long cones 142 form a substantially continuous surface with pad outer surface 152. The ends of squared cones 144 and the attached T-nuts are also exposed at surface 152 for attachment of assembly 153 at the inner surface of shell 10. In a preferred embodiment, pad assembly 153 is enclosed in an envelope consisting of a soft comfort pad 154 on the side of the pad facing the wearer, and a fabric backing 155 made of a material such as tricot on the side facing the inner surface of shell 10. It will be appreciated that the flat ends of long cones 142 contact the inner surface of shell 10, or have only the thin fabric layer 155 between the flat ends and the inner surface. This composite structure provides an area of reinforced shock absorption just above the front edge of shell 10, coinciding with the assembly of thin region 150 and TPU element 140, while higher up, the un-reinforced thick region 149 performs similarly to a conventional EVA brow pad. Thus, the subject technology may include a composite front pad, comprising a molded TPU shock absorber having frusto-conical projections extending from a base sheet, mated with a pad of molded foam material, the frusto-conical projections being received snugly into openings formed in the pad of molded foam material, the mated assembly fitted with a soft padded comfort layer. The composite front pad is especially well suited for use in protecting against the most forceful and frequent blows sustained in a full-contact sport, such as the blows received on the brow of a football helmet.
FIG. 40 shows a view of a lateral assembly of TPU shock absorbing elements that may be installed in the helmet 1 of the subject technology, in the rear area of the helmet, and extending to the left and right side areas of the helmet. FIGS. 41-43 show views of the central element of the assembly. FIGS. 44-45 show views of a top element of the assembly. FIGS. 62-63 show views of a left wing of the assembly. FIGS. 49-51 show views of a right wing of the assembly.
Turning first to FIG. 40, lateral TPU assembly 170 is composed of central TPU element 171, upper TPU element 172, right TPU element 173, and left TPU element 174. Elements 171, 172, 173, 174 may be formed integrally, or formed separately and attached together. When formed integrally, elements 171, 172, 173, 174 may be attached by living hinges of TPU material formed in the base sheet. When formed separately, each of elements 171, 172, 173, 174 may be formed with a tab at the periphery for bonding to corresponding tab of the neighboring element. The tabs may be bonded by any suitable means known to the art, including adhesives and plastic welding. Central TPU element 171 is connected to upper TPU element 172, right TPU element 173, and left TPU element 174, as shown.
Each of elements 171, 172, 173, 174 is generally similar in construction, in that each is formed of a TPU base sheet 176, 177, 178, 179, respectively, having hollow frusto-conical projections extending therefrom to provide shock absorption, 180, 181, 182, 183, respectively, (only one projection is numbered in each element). One or more of these TPU elements may be formed with a fence of TPU material, composed of base sheet material and running along one or more edges of the elements. In the embodiment of FIGS. 40-51, central TPU element 171, right TPU element 173, and left TPU element 174 each has such a fence of TPU material, numbered respectively 184, 185, 186, formed along the edges which face toward the open bottom of shell 1. Central TPU element 171 may be formed with keyway 187 for passage of a valve for an inflatable liner as hereinafter described. Central TPU element 171 may be composed of a central middle portion 190, a central right lobe 188, and central left lobe 189, integrally formed out of a single piece of TPU material. Central right lobe 188 and central left lobe 189 are each connected to central middle portion 190 by a bridge of base sheet material. Each of elements 171, 172, 173, 174 may have one or more squared hollow projections 191 with a T-nut at the distal end for attachment to the inner surface of shell 10.
FIGS. 102-104 show views of a TPU shock absorbing element having a dense distribution of cones, which may be used in a top area of helmet 1.
FIG. 16 shows a schematic rendering of TPU shock absorbing elements as hereinabove described installed on the inner surface of shell 10.
The inner padding elements of helmet 1 may include inflatable elements, which are particularly well adapted to custom-size helmet 1 to the wearer. In general construction, inflatable elements according to the subject technology are formed of bottom sheet and a top sheet of suitable material which may be TPU material. Recesses or pockets are formed in the top sheet. The recesses or pockets may contain pads; however, some recesses may be devoid of pads. The bottom sheet is bonded to the top sheet to seal the recesses or pockets and thereby form pressure-containing cells, which may be pressurized through a valve in fluid communication with the cells. Each of these inflatable elements or liners is inflated through a valve disposed in a tube, the tube extending through openings in the associated mobility layer, associated TPU shock absorbing element, and shell, so that the liners are inflatable from outside of helmet 1. FIGS. 55-59 show views of an inflatable lateral liner which may be used in helmet 1, which is installed in the rear area of the helmet and extends laterally left and right. FIGS. 74-75 show views of an inflatable crown liner which may be used in helmet 1, which is installed in the crown area of the helmet. FIGS. 99-101 show plan views of pads of resilient polymer foam material which may be disposed in the inflatable cells of the crown inflatable liner, having shapes which conform to the shapes of the respective cells.
Turning now to FIGS. 55-60, inflatable lateral liner 200 comprises a top sheet 201 of a suitable thin, flexible material such as TPU, vinyl, or the like, bonded to a bottom sheet 202 of such material. The overall liner 200 is sized and shaped to approximately overlie lateral TPU assembly 170. Pockets are formed in the top sheet 201, which when bonded to the bottom sheet 202 form air-containing cells 203, 204 (only one of each is numbered) in the liner 200. Cells 203, 204, are distributed over the area of the top sheet 201 facing the wearer, to provide comfort and shock absorption. Certain of the cells are inflatable, and are linked together by air-conducting passages 212 (only four are numbered) to permit passage of inflating air into the inflatable cells. Optionally, certain cells are non-inflatable and are not connected by passages. In a preferred embodiment, the non-inflatable cells are arranged at the top edge of liner 200 (i.e. the edge in the direction of the crown of helmet 1). Cells 203, 204, are preferably shaped so that they interlock as shown. In the illustrated embodiment, cells 203 are shaped as truncated triangles with concave sides, and cells 204 are crescent-shaped, thus enabling interlocking of the cells as shown. Other interlocking shapes, or non-interlocking shapes, could be used for the cells of liner 200. A valve assembly 205 is connected in fluid communication with one of the inflatable cells of liner 200 via inflation tube 206. Tube 206 passes through an opening in bottom sheet 202 to enable inflation of the cell to which it is connected, and the entire set of inflatable cells which are interconnected by passages 206. The opening is sealed around tube 206 for airtightness and to anchor tube 206 to bottom sheet 202. Liner 200 may be formed with a tab 207 having a hook-and-loop fastener 208 on top sheet 201. When liner 200 is installed, tab 207 is tucked behind lateral TPU assembly 170 and fastener 208 is mated with the opposite hook-and-loop fastener adhered to the inner surface of shell 10. Preferably, valve assembly 205 consists of valve 211, which may be a conventional needle-inflation valve, positioned within a mating tube 210. Mating tube 210 is mated to the distal end of inflation tube 206, and has a flange, which is covered on the shell-facing side with hook-and-loop fastener material. When installed, the distal end of mating tube 210 is inserted into a through-going hole in shell 10, and the flange is removably attached via its hook-and-loop fastener material to the opposite hook-and-loop fastener adhered adjacent to the through-going hole.
Turning now to FIGS. 74-75, inflatable crown liner 240 is similar in construction to inflatable lateral liner 200. Inflatable crown liner 240 comprises a top sheet 241 of a suitable thin, flexible material such as TPU, vinyl, or the like, bonded to a bottom sheet 242 of such material. The overall liner 240 is sized and shaped to approximately overlie crown TPU element 160. Pockets are formed in the top sheet 241, which when bonded to the bottom sheet 242 form air-containing cells 243, 244, 252 (only one of each is numbered) in the liner 240. Cells 243, 244, 252, are distributed over the area of the top sheet 241 facing the wearer, to provide comfort and shock absorption. Certain of the cells are inflatable, and are linked together by air-conducting passages 246 (only two are numbered) to permit passage of inflating air into the inflatable cells. In the embodiment shown, all cells of liner 240 are inflatable. Optionally, certain cells are non-inflatable and are not connected by passages. Cells 243, 244, are preferably shaped so that they interlock as shown. In the illustrated embodiment, cells 243 are shaped as truncated triangles with concave sides, cells 244 are crescent-shaped, and cell 252 is circular, thus enabling interlocking of the cells as shown. Other interlocking shapes, or non-interlocking shapes, could be used for the cells of liner 240. A valve assembly 245 is connected in fluid communication with one of the inflatable cells of liner 240 via inflation tube 247. Tube 247 passes through an opening in bottom sheet 242 to enable inflation of the cell 252 to which it is connected, and the entire set of inflatable cells which are interconnected by passages 246. The opening is sealed around tube 246 for airtightness and to anchor tube 247 to bottom sheet 242. Preferably, valve assembly 245 consists of valve 251, which may be a conventional needle-inflation valve, positioned within a mating tube 250. Mating tube 250 is mated to the distal end of inflation tube 247, and has an integral flange, which is covered on the shell-facing side with hook-and-loop fastener material. When installed, the distal end of mating tube 250 is inserted into a through-going hole in shell 10, and the flange is removably attached via its hook-and-loop fastener material to the opposite hook-and-loop fastener adhered adjacent to the through-going hole.
FIGS. 10-13 show a helmet 1 according to an embodiment of the present technology. FIGS. 10 and 13 show the placement of TPU shock absorbing elements and cheek supports, without the mobility layers and inflatable elements of the present technology (all of which are hereinafter described).
In addition to the TPU shock absorbing elements, the inner padding elements of helmet 1 may include mobility layers (also referred to as mobility liners) disposed between the inflatable liner elements and the TPU shock absorbing elements. Mobility layers according to the present technology may be composed of ethylene-vinyl acetate (EVA) polymer or a similar resilient polymer, with a backing of black loop fabric to mate with hook pads in a hook-and-loop fashion, the hook pads disposed on the other liner elements to removably attach the layers to said elements and within helmet 1. FIGS. 52-54 show views of a lateral mobility layer that is shaped and sized to be interposed between the lateral assembly of TPU shock absorbing elements and the lateral inflatable liner. FIGS. 71-73 show views of a crown mobility layer that is shaped and sized to be interposed between the the crown shock absorbing element and the crown inflatable liner. A mobility layer according to the subject technology incorporates bumps or domes on the side facing the TPU shock absorbing element or elements to reduce the area of contact and thereby reduce frictional forces between the mobility layers and the TPU shock absorbing elements. Alternatively, the bumps or domes could be disposed on the side facing the inflatable liner elements, or could be disposed on both sides of the mobility layer facing both the shock absorbing elements and inflatable liner elements. The interposition of the mobility layers between the TPU shock absorbing elements and the inflatable liner elements permits relative movement between the TPU shock absorbing elements and the inflatable liner elements when a shock force or blow is received on the helmet during sports play, which assists in protecting the head from being subjected to forces and from being accelerated by said forces. In this manner, the helmet shell 10 and attached TPU shock absorbing elements can move to some extent in a rotational or sliding direction without imparting the same amount or degree of movement to the inflatable liner elements and the wearer's head, which is in contact with the inflatable liner elements.
Turning now to FIGS. 52-54, for improved performance, a lateral mobility layer or lateral mobility layer 220 is provided, to be disposed or sandwiched between liner 200 and lateral TPU assembly 170. Lateral mobility layer 220 is molded from a suitable material, for example, EVA polymer. Mobility layer 220 is molded to have domes 221 (only one is numbered) distributed over one side of the liner and rising above the surface 224 of that side; the other side is backed with a fabric covering 222. A through-going hole 223 is formed in layer 220 to allow passage of valve assembly 205 and inflation tube 206. Mobility layer 220 is sized and shaped to approximately overlie lateral TPU assembly 170. The domed side of liner 220 has adhered to it hook-and-loop fastener pads 225 (only one is shown), which preferably are sparsely distributed.
As shown in FIGS. 61-62, mobility layer 220 is assembled to inflatable lateral liner 200 by mating fasteners 209 on bottom sheet 202 of liner 200 with fabric cover 222 of liner 220. When assembled, domes 221 face away from liner 200 (best seen in FIG. 62).
As best seen in FIGS. 63-64, the assembly of lateral liner 200, mobility layer 220, and lateral TPU assembly 170 results in a sandwich of mobility layer 220 between lateral liner 200 and lateral TPU assembly 170. Domes 221 of mobility layer 220 face toward and contact lateral TPU assembly 170 and provide a gap or clearance between the surface 224 of mobility layer 220 and the elements of lateral TPU assembly 170. The domes 221 thereby reduce the contact area between surface 224 and lateral TPU assembly 170, and thereby reduce the transmission of rotational or sliding force and movement of shell 10 and its attached lateral TPU assembly 170 to mobility layer 220 and lateral liner 200.
Turning now to FIGS. 72-73, according to the subject technology, a crown mobility layer or crown mobility layer 260 is provided, to be disposed or sandwiched between crown inflatable liner 240 and crown TPU element 160. Crown mobility layer 260 is similar in form to lateral mobility layer 220 and is molded from a suitable material, for example, EVA polymer. Mobility layer 260 is molded to have domes 261 (only one is numbered) distributed over one side of the liner and rising above the surface 264 of that side; the other side is backed with a fabric covering 262. A through-going hole or cutaway 263 is formed in layer 260 to allow passage of valve assembly 245 and inflation tube 247. Mobility layer 260 is sized and shaped to approximately overlie crown TPU element 160. The domed side of liner 260 has adhered to it hook-and-loop fastener pads 265 (only one is numbered), which preferably are sparsely distributed. Holes 266 may also be provided in liner 260 to provide access to the T-nuts affixing crown TPU element 160 to shell 10.
FIGS. 76-77 show views of the assembly of the crown inflatable liner 240, crown mobility layer 260, and crown TPU shock absorbing element 160. The inflation tube 247 of the crown inflatable liner 240 extends through openings in the crown mobility layer and crown TPU element 160 (through keyway 165) and is retained by keyway retaining projections 166. A valve assembly is assembled to the end of the tube, including an annular rim lined with hook-and-loop material for securing the valve assembly to the inner surface of shell 10, so the valve remains in its place at an opening in shell 10 for inflation.
Turning now to FIGS. 99-101, the cells of lateral inflatable liner 200 and crown inflatable liner 240 may contain pads of foam material, for example, Omalon foam, to provide additional cushioning performance. Preferably, the pads are shaped to fit their cells, for example, pad 230 for crescent cells 204, 244; pad 231 for circular cell 252; and pad 232 for triangular cells 203, 243.
A face guard 270 may be removably attached to shell 10. Face guard 150 may be in the form of a cage of metal wire, titanium wire, steel wire, or aluminum wire, and which may be coated overall with a polymer coating. FIGS. 105-128 show front and left-side views of various face guard designs which may be used in helmet 1 according to the subject technology, according to the wearer's needs and playing position.
Face guard 270 may be attached above front edge 29 of shell 10 by a twist-release mount such as that disclosed in U.S. Pat. No. 8,146,178, or in U.S. Patent Application Ser. No. 29/616,447, the entire disclosure of both of which are hereby incorporated by reference, both of which are assigned to the assignee of the present application. FIGS. 78-82 show views of a twist-release mount which may be used in helmet 1.
Face guard 270 may be attached to shell 10 at the left edge 30 and right edge 31 by conventional loop straps attached to shell 10 with screws, bolts, or T-nuts. The loop straps may be attached to shell 10 with a partial-turn faceguard mounting such as those disclosed in U.S. Pat. No. 8,819,871 for “Helmet with partial turn faceguard mounting,” the entire disclosure of which is hereby incorporated by reference, which is assigned to the assignee of the present application. Alternatively, in place of conventional loop straps, face guard retainers may be used, such as those disclosed in co-pending U.S. patent application Ser. No. 15/380,508 for “Improved Helmet Faceguard Retaining Device,” the entire disclosure of which is hereby incorporated by reference, which is assigned to the assignee of the present application.
While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles. It will also be understood that the present invention includes any combination of the features and elements disclosed herein and any combination of equivalent features. The exemplary embodiments shown herein are presented for the purposes of illustration only and are not meant to limit the scope of the invention.
Patent Application
20230019358
