Patent Application
20140373257
Non-limiting and non-exhaustive embodiments of the disclosure are provided herein, including various embodiments of the disclosure illustrated in the figures listed below.
In the following description, numerous specific details are provided for a thorough understanding of the various embodiments disclosed herein. The systems and methods disclosed herein can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In addition, in some cases, well-known structures, materials, or operations may not be shown or described in detail in order to avoid obscuring aspects of the disclosure. Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more alternative embodiments.
Embodiments may be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. It will be readily understood that the elements, materials, and components of the present disclosure, as generally described and illustrated in the drawings herein, could be arranged and designed in a wide variety of different configurations and embodiments. Thus, the following more detailed description of the embodiments of the apparatus is not intended to limit the scope of the disclosure, but is merely representative of possible embodiments of the disclosure. In some cases, well-known structures, materials, or operations are not shown or described in detail in order to avoid obscuring aspects of the disclosure. Furthermore, the described features, structures, steps, or characteristics may be combined in any suitable manner in one or more alternative embodiments and/or implementations.
The present disclosure provides various embodiments of layered shell configurations that may be used in various protective gear items, such as helmets. In some embodiments, the layered shell may be configured to provide for improved protection at multiple velocities. For example, some embodiments may be configured to provide improved impact protection during relatively high velocity impacts and also relatively low velocity impacts. Some embodiments may be also, or alternatively, be configured to provide improved protection and/or durability for multiple impacts at the same portion of the helmet over time. Some embodiments may also allow for providing a substantially thinner layer of protective structure than traditional helmets or other protective gear, while still providing one or more of the improved impact protection features mentioned herein.
Some embodiments may comprise helmets, such as helmets for use in motorcycling, skiing, snowboarding, skateboarding, and the like, comprising an interior structure that provides significant reduction in g-force impacts to the head from high velocity and low velocity impacts. In some embodiments, the helmet may also, or alternatively, provide significantly more multiple impact protection than currently available protective interior structures.
Some embodiments may comprise a protective structure comprising multiple layers of different materials having different thicknesses and densities that are arranged and configured to interact with one another in a manner so as to cushion the head (in embodiments incorporated into helmets) and protect the head from impacts by dissipating energy from both the outside of the helmet (area of impact) and from the interior of the helmet by reducing the deceleration velocity of the head during an impact. Some embodiments, as described in greater detail below, may comprise three distinct layers each comprising different materials arranged relative to one another and comprising preselected thicknesses that improve impact protection.
In some such embodiments, the outermost layer may comprise a relatively thick layer made up of a crushable foam material or another material having similar properties. The middle layer may comprise a relatively thin layer made up of a hard plastic material or another material having similar properties configured to spread energy from an impact across a larger area to dissipate the energy transfer to the head associated with the impact. The innermost layer may comprise a material having properties that allow it to compress and rebound, preferably with little deterioration in shock absorbing properties, such as an ethylene-vinyl acetate (EVA) foam or a non-newtonian foam such as a PORON® foam. Although the thickness of the inner layer may vary depending upon the desired or intended impact protection characteristics, preferably the thickness of the inner and outer layers are both substantially greater than the thickness of the middle layer of the protective structure. In some embodiments, the thickness of the inner layer may be in between that of the outermost layer and the middle layer of the protective structure.
Additional details of certain embodiments and implementations will now be discussed in greater detail with reference to the accompanying drawings.
More particularly, inner shell 120 comprises an outer layer 122, a middle layer 124, and an inner layer 126. Preferably, the materials and thicknesses of the three layers are selected and arranged to interact with one another during an impact so as to improve impact protection characteristics. In some embodiments, the materials and thicknesses of the three layers may be selected and arranged to interact with one another during an impact so as to improve impact protection characteristics associated with both high velocity and low velocity impacts. Additionally, or alternatively, the materials and thicknesses of the three layers may be selected and arranged to interact with one another during an impact so as to improve impact protection characteristics associated with repeated impacts at the same, or at least generally the same, location on the helmet over time.
In some preferred embodiments, the density of the material(s) making up middle layer 124 is greater than the density of the material(s) making up either of the other two layers. Middle layer may comprise a relatively rigid, hard material, such as a hard plastic material. In some such embodiments, the density of outer layer 122 is greater than the density of inner layer 126. It has been discovered that such configurations result in an improved energy transfer and absorption between the three layers that results in improved impact protection.
In some embodiments, outer layer 122 may comprise a material having energy absorption characteristics, such as a foam material. Preferably, outer layer 122 comprises a compressible material. In some such embodiments, outer layer 122 may comprise a crushable foam material. Examples of suitable materials for outer layer 122 that have desired energy absorption characteristics include EPS (expanded polystyrene) and EPP (expanded polypropylene). In some preferred embodiments, the density of the material making up outer layer 122 may be between about 20 g/l and about 85 g/l. In some such embodiments, the density of the material making up outer layer 122 may be between about 40 g/l and about 85 g/l. In some such embodiments, the density of the material making up outer layer 122 may be between about 30 g/l and about 80 g/l. In some such embodiments, the density of the material making up outer layer 122 may be between about 20 g/l and about 40 g/l. In some such embodiments, the density of the material making up outer layer 122 may be between about 60 g/l and about 85 g/l.
In some preferred embodiments, the thickness of outer layer 122 may be between about 5 mm and about 30 mm. In some such embodiments, the thickness of outer layer 122 may be between about 10 mm and about 30 mm. In some such embodiments, the thickness of outer layer 122 may be between about 10 mm and about 20 mm. It appears that these ranges and materials provide for improved protection from low velocity impacts, high velocity impacts, and multiple impacts.
In some embodiments, middle layer 124 may comprise a relatively rigid, non-compressible, and thinner layer of material. For example, middle layer 124 may comprise an acrylonitrile butadiene styrene (ABS) plastic or another material with similar properties, such as a fiberglass, carbon fiber material, and the like. In some preferred embodiments, middle layer 124 may comprise a thickness of between about 1 mm and about 2 mm. As described in greater detail below, preferably middle layer 124 is configured and arranged to isolate and/or spread forces and accompanying energy associated with exterior impacts from/across inner layer 126. Middle layer 124 may also be configured to serve as a barrier to protect against penetration by sharp objects, such as rocks, wood splinters, and the like. Middle layer 124 may comprise an at least substantially smooth surface, and may further, or alternatively, comprise a support in the form of a supported edge crimp, which may be useful for ventilation. Such a crimp or crimps may also be useful in increasing the rigidity of middle layer 124 and/or improving the functionality of the protective structure by improving the ability of the middle layer 124 to spread or otherwise distribute forces between the outer layer 122 and the inner layer 126, as discussed below in connection with
In some embodiments, inner layer 126 comprises a compressible, resilient material, preferably configured to avoid crushing deformation that would be associated with certain preferred embodiments of outer layer 122 during high velocity impacts. Suitable materials include, for example, ethylene-vinyl acetate (EVA) foam or a non-newtonian foam such as a PORON® foam. In some preferred embodiments, inner layer 126 comprises a softer material than the material making up either of the other two layers, so as to provide cushion to a head or other body portion during an impact. In some preferred embodiments, inner layer 126 may comprise a thickness of between about 3 mm and about 20 mm. In some such embodiments, inner layer 126 may comprise a thickness of between about 5 mm and about 15 mm. In some such embodiments, inner layer 126 may comprise a thickness of between about 5 mm and about 10 mm. In embodiments comprising an inner layer of EVA, such material making up the inner layer 126 may have a SHORE-A hardness value of between about 20 and about 70.
This combination of layers of different materials having preselected properties better protects against both high and low velocity impacts to a helmet or other protective gear item. In some embodiments, this combination of layers of different materials having preselected properties also provides improved protection against multiple low-velocity impacts. Without being limited by theory, it is thought that these improvements, and others, may be obtained as follows.
During relatively high velocity impacts, outer layer 122, which provides impact absorption from the impact arriving from the outside of the helmet, deforms and/or crushes the crushable foam or other similar material making up outer layer 122, thereby absorbing and releasing energy from the impact. For purposes of this disclosure, “high velocity” impacts should be considered to encompass those defined by the ASTM vertical drop specifications for helmets and “low velocity” impacts should be considered those at or less than one-half of those defined by the ASTM vertical drop specifications for helmets, which may vary depending on the intended use of the helmet. The middle layer 124 then isolates, or at least reduces, the impact and energy transferred to the inner layer 126. Middle layer 124 may also be configured to spread the impact energy across a larger area of inner layer 126, thereby resulting in significantly lower energy transfer to the head and increased time of head deceleration.
Again, without being limited by theory, during relatively low velocity impacts, inner layer 126 may compress as the head pushes into the foam or other material making up inner layer 126, thereby decelerating the head. The outer layer 122 may provide limited, but important, energy absorption, and may spread the low velocity impact across a larger area, thereby reducing its transfer towards the head. The middle layer 124 may both isolate the exterior impact from the inner layer 126 and isolate the interior layer impact from the outer layer 122.
It is thought that the inventive structures disclosed herein also provide improved protection from multiple, low velocity impacts and improved durability resulting from such impacts. More particularly, without being limited by theory, it appears that, since the inner layer 126 primarily functions to decelerate the head during such impacts (for embodiments in which the layered protective structure comprises a helmet), the use of compressible, resilient foam materials, or other materials with similar properties, allows inner layer 126 to maintain its absorption properties through repeated compressions and expansions while conforming back to its original shape, thereby enhancing durability as well as impact protection.
Through testing, it has been determined that the embodiments and inventive concepts described herein significantly improve g-force management (reduced g forces) from high velocity impacts consistent with, for example, motorsports, as well as low velocity impacts, relative to existing helmet technology. Additionally, the embodiments and inventive concepts described herein may provide improved g-force management and/or durability from repeated impacts. These experimental results are summarized in the examples listed below.
Tests were performed on several currently available helmets within the motorcycle, bike, snow sport, and skateboard industries at specific speeds, drop heights and anvils.
The results indicate that the design described herein results in significantly superior g force reduction compared to currently available helmets. More particularly, as shown in
The results from a second test at a drop height of about 78 cm (about 3.89 m/s impact speed) are even more dramatic in illustrating the improvements available from incorporating the inventive concepts described herein into helmets and/or other protective gear. As shown in
The results from a third test at a drop height of about 160 cm (about 5.59 m/s impact speed) illustrate that the benefits from incorporating the inventive concepts described herein into helmets and/or other protective gear continue for high velocity impacts. As again shown in
As illustrated by each of the above-referenced examples, helmets incorporating protective structures according to the invention may achieve substantially-improved performance over related helmets for all three impact velocities. In fact, as also illustrated by each of these experimental working examples, helmets incorporating protective structures according to the invention experienced g-forces for each of the three drop heights that were less than or equal to about 100 g's, which is currently considered to be the desired threshold for concussion avoidance.
Despite this improved performance, some embodiments may be configured to provide such protection with a smaller thickness than most other protective structures. Indeed, in some embodiments, the combined thickness of the three layers of the protective structure may be less than about 30 mm. In some such embodiments, the combined thickness of the three layers may be less than or equal to about 24 mm. Indeed, the helmet used in the above-referenced test results had a thickness of only about 24 mm, including the exterior shell of the helmet, at its thickest point. The helmet used in this testing comprised an outer layer of EPS foam having a thickness of about 10 mm, a middle layer of ABS plastic having a thickness of about 1 mm, and an inner layer of EVA foam having a thickness of about 11 mm.
The g forces associated with the helmet incorporating a layered inner shell according to one embodiment of the invention is shown at line 502. Similarly, the g forces associated with two other helmets (neither of which obtained the worst result shown in
As shown in
The g forces associated with the helmet incorporating a layered inner shell according to the embodiment of the invention used in the experiment depicted in
As shown in
The g forces associated with the helmet incorporating a layered inner shell according to the embodiment of the invention used in the experiment depicted in
As shown in
It should be noted that, upon reviewing and comparing
The openings 802 may correspond with vent openings in the outer shell of, for example, a helmet. However, in addition to serving this venting purpose, providing a crimp on a middle layer of a layered protective structure may serve to improve the function of the protective structure. As such, it is contemplated that, in some embodiments, such a middle layer may comprise one or more crimped walls even if such walls do not necessarily define an opening in the middle layer. In other words, in some embodiments, one or more crimps or similar structures may be provided to increase rigidity or otherwise improve the function of a layered protective structure, such as by improving the ability of the middle layer to spread forces between one or more inner and/or outer layers, irrespective of whether such structures also define openings, such as vent openings.
As depicted in
Openings 902 may, in some embodiments, may be aligned with vent openings in the outer shell of, for example, a helmet. As mentioned above, the raised/crimped structures surrounding openings 902 may be provided to increase rigidity or otherwise improve the function of a layered protective structure, such as by improving the ability of the middle layer to spread forces between one or more inner and/or outer layers.
Middle layer 900 also comprises a second honeycomb structure comprising non-crimped openings 910. Openings 910 may, like openings 902, be formed as hexagons or other polygons and may be arranged such that each side of the polygonal opening is positioned adjacent to a corresponding side of an adjacent polygonal opening 910.
Additional tests were performed using embodiments described herein, the results of which further establish significant improvement relative to existing helmet technology. These further experimental results are summarized in the additional examples listed below.
Tests were performed on several currently available helmets at specific drop heights to assess peak linear acceleration, peak angular acceleration, and Head Injury Criterion (“HIC”), which is a commonly-used measure of the likelihood of head injury resulting from an impact with a helmet. Table 1 below summarizes the results of these experiments at a drop height of 51 cm.
The table above compares the results of tests at a drop height of 51 cm for a helmet incorporating a layered, inner shell according to one embodiment of the invention disclosed herein (“Embodiment”) compared with those from a typical, off-the-shelf helmet (“Base”) and those from a particular, high-end brand of helmet (MIPS).
Table 2 below summarizes the results of these experiments at a drop height of 77 cm.
Table 3 below summarizes the results of these experiments at a drop height of 206 cm.
These results indicate that the design described herein results in significantly better HIC scores, which translate to fewer and less severe injuries.
The foregoing specification has been described with reference to various embodiments. However, one of ordinary skill in the art will appreciate that various modifications and changes can be made without departing from the scope of the present disclosure. Accordingly, this disclosure is to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope thereof. Likewise, benefits, other advantages, and solutions to problems have been described above with regard to various embodiments. However, benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, a required, or an essential feature or element. The scope of the present invention should, therefore, be determined only by the following claims.
This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 61/839,314 filed Jun. 25, 2013 and titled “LAYERED PROTECTIVE STRUCTURES FOR PROTECTIVE GEAR,” which application is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61839314 | Jun 2013 | US |
