Patent Application
20170280811
The present invention relates to protective headgear, such as a helmet for contact sports or recreational activities and, more particularly, to protective headgear having a non-rigid outer shell, a lightweight metal frame, and interior cushioning, combined in a manner to lessen the risks of head and neck injuries to the wearer.
It has become well-known and widely reported that there has been an increase in head, neck and brain injuries sustained by athletes engaged in contact sports such as football, hockey, lacrosse, and the like.
While there have been many attempts to address this concern, such as by incorporating various types of shock absorbing material within the helmet, webbing within the helmet, modular components located at strategic areas of the helmet, etc., every contemplated modification remains based on the utilization of the hard plastic outer shell as a basic and necessary component of the helmet structure.
The limitations in the prior art are addressed by the present invention, which relates to protective headgear (used, for example, in any type of contact sport or recreational activity) that eliminates the need to use a hard plastic outer shell.
In accordance with the present invention, an exemplary protective headgear apparatus (hereinafter referred to as a “helmet”) is formed to comprise a non-rigid outer shell in the form of multiple layers of open-cell foam, each layer having a different density. A flexible, lightweight metal frame (i.e., a “cage”) is disposed to contact the inner surface of the outer shell (i.e., bonded in a manner that essentially “locks” the frame to the foam layer), and an open-cell foam cushion layer (in a waffle-like pattern) is bonded to the exposed surface of the metal frame.
The various foam layers are preferably impregnated with activated carbon particles that electrostatically absorb (i.e., “capture”) the energy caused by blows to the outer shell. The captured energy is thereafter distributed throughout the volume of the foam layer itself, so as to minimize the amount of energy that reaches the wearer's head.
In some embodiments of the present invention, various styles of face mask, formed of a tensile strength metal alloy, may be welded or bolted to the headframe and, therefore, also be capable of withstanding severe contact blows. In preferred embodiments, the face mask is fitted with a shatter-proof, ventilated, acrylic shield to create a smooth surface over the mask and prevent opposing players from the grabbing the mask (intentionally or unintentionally), thus minimizing the possibility of serious neck injuries.
One exemplary embodiment takes the form of protective headgear apparatus comprising: a plurality of layers of open-cell foam forming a multi-layer, non-rigid outer shell, a lightweight metal frame forming a desired headgear configuration, with the multi-layer, non-rigid outer shell disposed over and covering the lightweight metal frame, and an inner cushion component coupled to exposed underside of the lightweight metal frame and disposed to cover at least portions of the lightweight metal frame associated with selected areas of a user's head.
Other and further embodiments of the present invention will become apparent during the course of the following discussion and by reference to the accompanying drawings.
Referring now to the drawings, where like numerals represent like parts in several views:
In accordance with the present invention, the use of a non-rigid, foam-based, multilayer outer shell functions to spread the energy associated with a “hit” across a larger surface area of the protective headgear (hereinafter referred to as “helmet”) than could be achieved with the prior art hard plastic shell helmet. Additionally, one or more of the layers of the outer shell is impregnated with activated carbon particles to enhance the energy absorption. Alternatively, a separate layer of the activated carbon may be disposed between adjacent foam layers. A cage-like frame of a lightweight metal composition (e.g., aluminum or an aluminum alloy) is positioned between the non-rigid outer shell and an interior cushion (the cushion resting against the user's head). The frame functions, in accordance with the present invention, to further dissipate the energy associated with a blow to the helmet, reflecting some of the energy outward and away from the player. In some embodiments, the frame may be formed to include an integral face mask element. The details of the inventive design will now be explained below in association with the provided drawings.
In particular, the multiple layers of non-rigid outer shell 12 are organized such that they increase in density from outer surface 12-S to inner surface 12-I. For example, a first layer 12-1 may comprise an open-cell foam having a density in the range of 20-40%, a second layer 12-2 may comprise an open-cell form having a density in the range of 40-60%, and a third layer 12-3 may comprise an open-cell foam having a density in the range of 60-80%. These values are all considered to be exemplary only, and other combinations of density (as well as other numbers of separate layers) may be used in the formation of non-rigid outer shell 12.
In the fabrication of this multi-layer non-rigid outer shell, a flexible coating 12-4 (e.g., vinyl or another appropriate plastic) may be included on the outer surface 12-S of shell 12. Flexible coating 12-4 is useful in allowing various coloring designs and combinations (including team logos) to be presented on the surface of the helmet. It is to be understood that by its nature of being “flexible”, coating 12-4 is also non-rigid and, therefore, does not affect the energy absorption properties of non-helmet 10. In one embodiment, layer 12-1 was formed to have a thickness of about a quarter inch, with layer 12-2 also formed of a quarter-inch thickness and layer 12-3 having a thickness on the order of three-eighths of an inch (i.e., an overall thickness of non-rigid outer shell 12 being less than one inch).
In further accordance with the present invention, at least one layer of non-rigid outer shell 12 is formed to include activated carbon particles 13. Activated carbon particles 13 function to electrostatically absorb the energy associated with forces applied to the helmet (i.e., from contact with another player, other equipment, hitting the ground when falling, etc.). Indeed, the individual activated carbon particles 13 capture the incoming energy, and then function to instantly re-direct this energy across the surface (and into the volume) of the associated foam layer, preventing most, if not all, of this energy from reaching the individual's head. As a result of the presence of carbon particles 13, the energy associated with these externally-applied forces is maintained at a safe distance and well-separated from the wearer's head and neck.
It is to be understood that the specific number of open cell foam layers used to form non-rigid outer shell 12 may vary, as well as the specific densities of each layer. However, it is preferred that the density of each layer increases in the direction from the exterior to the interior of the helmet.
Lightweight metal frame 14 integrates with layer 12-3 upon formation. In a preferred embodiment, frame 14 comprises aluminum or an aluminum alloy. Aluminum is known to be a lightweight, high tensile strength metal that is capable of redirecting applied forces, in this case functioning in a spring-like manner to re-direct the absorbed energy back into outer shell 12. In one exemplary embodiment, a magnesium-aluminum alloy was utilized, which exhibited an appropriate flexibility, while only having a thickness on the order of 3/16″. Other materials may be used in combination with aluminum, such as scandium (or a combination of magnesium and scandium). In accordance with the present invention and as mentioned above, frame 14 is sufficiently flexible so that it reacts upon receiving an impact by springing back and deflecting the energy in the opposite direction; that is, deflecting the energy back into the multiple layers forming non-rigid outer shell 12. It is to be understood that aluminum alloy frame 14 is a primary element of the inventive helmet that prevents fractures by directing absorbed energy away from the individual's head and back into the outer shell 12.
Inner cushion 16, as shown in
Inner cushion 16 is also shown in
Lightweight metal frame 14 is again shown as comprising a cage-like structure that protects the head, including the forehead and neck regions. As mentioned above, in this particular embodiment, frame 14 further includes a forward portion that serves as a face mask 14-F. By virtue of integrating the face mask with frame 14, the possibilities of injuries associated with the facemask are further reduced. That is, the incorporation of the face mask with the helmet frame eliminates the bulky face masks bolted to helmets. In a preferred embodiment, face mask 14-F is covered with a clear acrylic coating 14-C (including a number of small ventilation holes), where coating 14-C is considered to further limit the ability of an opposing player to “grab” the face mask framework.
In this particular embodiment of the present invention, as shown in
It is to be understood that the inventive helmet relies on the interworking and cooperation of all three elements; forming a “matrix” structure that is able to receive hits and absorb energy in a manner far superior to prior art helmets that are based on the standard hard plastic outer shell. Indeed, the configuration of the present invention as shown and described will absorb, dissipate and deflect a significant portion of the impact energy caused by violent contact before the energy reaches the player's head. The flexibility of non-rigid outer shell 12 causes the energy from an impact to immediately fan out, dispersing the energy in a wide radius. The changes in density through the various layers forming shell 12 changes the propagation speed of the energy (i.e., slowing down the movement of the energy toward the head). The inclusion of lightweight metal frame 14 further disrupts the flow of the remaining energy, spreading the impact across the surface of frame 14. By virtue of its flexibility, frame 14 functions as a spring-like member, “kicking” the energy back into multi-layer outer shell 12, thus further minimizing the forces felt by the player.
As mentioned above, inner cushion 16 is preferably formed of an open cell foam having a waffle-like pattern, and fits closely to the player's head. Its contribution to the design is to cushion the player's head, preventing any residual impact force or energy from reaching the brain. Advantageously, the waffle pattern allows air to circulate and absorb moisture, increasing player comfort. In a preferred embodiment, inner cushion 16 is removable from the helmet structure, so that it can be replaced if it gets wet, becomes torn, etc.
Summarizing, the present invention describes a helmet that does not use a rigid plastic outer shell. The inventive design relies instead of an alternative foundation, one that does not transmit forced energy to the player's head. The inventive helmet consists of a three-part matrix formulation: (1) a one-piece, open metal framework of flexible, lightweight material that covers the head. This framework is encased solidly between (2) a thick outer padding (open-cell foam layers of increasing density, preferably incorporating activated carbon particles) that covers the entire framework and (3) an inner foam cushion that surrounds the player's head.
This configuration, in accordance with the present invention, is able to absorb and dissipate a significant portion of the energy produced by an initial impact, as associated with contact from an opposing player (or object). This is possible as a result of the performance qualities of the specific materials used to form each component of the three-part matrix formulation.
As described above, although the present invention has been explained by way of limited examples, the present invention is not intended to be limited thereby, and any person having ordinary skill in the art to which the present invention pertains will be able to carry out various modifications that are considered to fall within the spirit and scope of the present invention. Indeed, the scope of the present invention is intended to be limited only by the metes and bounds of the claims as appended hereto.
This application claims the benefit of U.S. Provisional Application Ser. No. 62/317,838, filed Apr. 4, 2016 and herein incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 62317838 | Apr 2016 | US |
