Patent Application
20210085011
The present invention relates to devices and methods for optimizing a protective helmet or other item of protective clothing with various impact and/or protection zones, some or all of which incorporate flexible, pliable and/or “softer” protective features that, in various embodiments, could be particularized to a specific sport, player-position and/or the individual behavior of a specific player. More specifically, the present invention relates to devices and methods that can be utilized to protect an athlete or other individual from a variety of incidental impacts (i.e., hitting another player and/or having their head strike the ground or goal post) as well as single and/or repetitive head impacts from relatively high speed, “lighter” objects during sports such as footballs, lacrosse balls, softballs, soccer balls, basketballs, baseballs, field hockey pucks, rugby balls, jai alai balls and/or water polo balls.
Many modern organized sports employ substantial “hard and/or flexible shell” helmets that are designed to provide players with significant head protection from intentional and/or unintentional impacts, including substantial impacts having a significant potential to cause traumatic brain injuries (TBI). However, many shell helmet designs are fairly bulky and heavy, and they often limit a player's visibility and “field awareness” when worn. Moreover, research suggests that the protection provided by shell helmets may result in a higher incidence of hits involving the player's head, in that the shell helmet may cause the player to develop a feeling of “invulnerability,” possibly leading the player to “lead with their helmet” during collisions. Furthermore, the use of hard shell helmets may be limited in some sports (e.g., soccer, rugby and women's lacrosse) due to the requirements and/or traditions within the game.
Soccer (also called “football” outside of the United States of America) is one of the world's most popular sports. Like many athletic activities, soccer involves some risk of injury, including head injury. While intentional contact between soccer players is highly discouraged, head injuries in soccer can include head collisions with another player's head, elbow, knee, or foot, as well as injuries when the head collides into a goal post, the ground or some other object.
A less well-known cause of head injury in soccer and other sports is the use of the head by a player to redirect a soccer ball in a desired direction at a desired speed, in what is typically called a “header.” Many studies have shown that “heading” a soccer ball (or similar repetitive impacts) can cause minor cumulative brain damage. Many soccer players who repeatedly headed the ball during their careers have been found to have chronic changes on their electroencephalograms (EEGs), in many ways similar to the changes found in amateur boxers. These players were found to have chronic mild to severe deficits in attention, concentration, memory, and judgement. More importantly, children, who have had significantly less exposure to heading a soccer ball that their professional counterparts (but who do play soccer on a frequent basis) have been found to have greater changes in their EEGs.
While hard shell-type helmets are conventionally used in most sports which involve a risk of head injury from one or more major impact events, such as American football, baseball, ice hockey, lacrosse, cycling, skiing, snowboarding, kayaking, equestrian sports, and rock climbing, such hard shell helmets can often interfere with the “play” and/or enjoyment of a sport, such as seriously interfering with a soccer player's ability to “head” a ball—thus interfering with the very nature of the sport of soccer. Thus, conventional helmets are not used in soccer, even though there is a significant risk of head injury.
The present invention includes the realization of a need for a lightweight, flexible, form-fitting protective helmet for various occupations and participants of sports and sporting activities where a more substantial and/or heavier rigid or shell-type helmet may be undesirable for a variety of reasons. More specifically, the soft-shell helmet or soft helmet should provide protection for both “ball-to-head” related impacts and “non-ball” related impacts (e.g., head-to-head, elbow-to-head, head-to-ground, etc.). The protective helmet or soft-shell helmet may comprise a partial head coverage or full head coverage protection.
In at least one exemplary embodiment, a “soft” shell helmet can include a protective headband. The protective headband can protect at least a portion of the head. The protective headband may comprise a tubular or generally cylindrical shape and configuration, which desirably fits around an upper portion of the wearer's head (i.e., across the forehead and above a portion of the ears). The headband may comprise at least one or more padded regions and at least one boot layer. The at least one boot layer may comprise one single material layer or two or more material layers. In one preferred embodiment, the at least one boot layer may comprise at least one first material, at least one second material, and at least one foam material and/or layer, the at least one foam material and/or layer being affixed to the at least one first and at least one second material. The at least one first or at least one second material may be a two- or four-way stretch fabric, where the top and bottom covering may be the same material or the at least one top and bottom covering may be different materials. The at least one or more padded regions comprising one more individual impact pads, which can be separated by one or more stretchable regions. In various embodiments, the stretchable regions can comprise one or more layers of elastic material or “two- or four-way stretch fabric,” which can allow the helmet to be expanded and/or contracted to accommodate heads of differing shapes, sizes and/or configurations, as well as to accommodate different wearing positions and/or styles by the player. Various embodiments can further include lower portions for extending along the sides, face and/or jaws of the wearer, as well as an optional peak or domed portion for protecting the top of the wearer's head. In various embodiments, the padded regions may protect the forehead, temples, and the occipital bone in the back of the wearer's head.
In one exemplary embodiment, a soft-shell helmet may comprise a full-coverage or full-face soft-shell helmet. The full-coverage helmet may cover the entire head, with a rear that covers the base of the skull, and a protective section that may cover the front of the chin and temples. Such full coverage helmets desirably have an open cutout to allow access to the face.
The full-coverage soft-shell helmet can comprise at least one of a boot layer or liner, at least one impact pad, at least one optional ear cover (which may comprise a removable and/or replaceable separate ear cover), a chinstrap, and/or any combination thereof. The at least one boot layer may comprise one single material or two or more materials. The at least one boot layer may further comprise an impact mitigation layer. In one preferred embodiment, the at least one boot layer may comprise at least one first material, a second material, and a foam layer material, the foam layer being affixed to the first and second material and disposed between the first and second material. The at least one ear cover and/or the chinstrap may be removably coupled to the soft-shell full-coverage helmet. The at least one or more individual impact mitigation pads may be directly affixed to the boot layer or liner. The impact mitigation pads may be desirably positioned on different regions of the head, including the frontal section, top or ridge section, lower back, mid-back, left side and front side, temples, jaw region and/or any combination thereof. The at least one or more individual impact pads may comprise at least one impact structure that can be affixed to the boot layer in desired regional locations to enhance impact protection. The at least one or more individual impact pads may further comprise a foam layer.
In various embodiments, the soft-shell helmet may optionally not incorporate an ear cover and/or may comprise a perforated portion of the helmet and/or may comprise a material capable of reasonable levels of sound transmission therethrough.
In another exemplary embodiment, the at least one or more individual impact pads may further comprise at least one impact structure, at least one first layer and at least one second layer. The at least one first layer or the at least one second layer may include a foam layer, polycarbonate layer, a hotmelt layer, a 2-way stretch material, a 4-way stretch material, Lycra, Ducksan Power Net, Neoprene, and/or any combination thereof. The polycarbonate layer can be thin, flexible, yet substantially rigid to assist with absorption of the forces and reduce wear/tear. The foam layer can include polymeric foams, quantum foam, polyethylene foam, polyurethane foam (PU foam rubber), XPS foam, polystyrene, phenolic, memory foam (traditional, open cell, or gel), impact absorbing foam, compression foam, latex rubber foam, convoluted foam (“egg create foam”), EVA foam, VN 600 foam, Evlon foam, Ariaprene or Ariaprene-like material, impact hardening foam, and/or any combination thereof. The at least one foam layer may have an open-cell structure or closed-cell structure. The foam layer can be further tailored to obtain specific characteristics, such as anti-static, breathable, conductive, hydrophilic, high-tensile, high-tear, controlled elongation, and/or any combination thereof.
In another exemplary embodiment, the at least one or more individual impact pads may further comprise at least one impact structure assembly, at least one first layer and at least one second layer. Alternatively, the at least one or more individual impact pads may further comprise at least one impact structure assembly, at least one foam layer, at least one first layer and at least one second layer. The impact structure assembly may comprise a two-piece assembly that comprises an impact mitigation structure and a first layer. The first layer may comprise a recess forming a pocket and a flange, the pocket may be shaped and configured to receive the impact mitigation structure, the impact mitigation structure disposed within the pocket. The at least one second layer may be affixed to the at least one first layer, impact mitigation structure, at least one second layer, and/or any combination thereof. Alternatively, the impact structure assembly may comprise a one-piece assembly that integrates the impact mitigation structure within the first layer. The one-piece impact mitigation structure assembly is comprised of a first layer and an impact mitigation structure that may be thermoformed, injection molded, 3D printed, casted and/or die cut as a one-piece construct.
The at least one first layer and/or the at least one second layer may comprise a single layer or multiple layers. Each of the at least one first layer and/or the each of the at least one second layer may comprise a 2-way stretch material, a 4-way stretch material, a foam layer, a polycarbonate layer, a hotmelt layer, a boot layer, Lycra, Ducksan and/or any combination thereof. The polycarbonate layer can be thin, flexible, yet substantially rigid to assist with absorption of the forces and reduce wear/tear. The foam layer can include polymeric foams, quantum foam, polyethylene foam, polyurethane foam (PU foam rubber), XPS foam, polystyrene, phenolic, memory foam (traditional, open cell, or gel), impact absorbing foam, latex rubber foam, convoluted foam (“egg create foam”), EVA foam, VN600 foam, Evlon foam, Ariaprene or Ariaprene-like material, impact hardening foam, compression and/or any combination thereof. The at least one foam layer may have an open-cell structure or closed-cell structure.
In one exemplary embodiment, the at least one or more individual impact pads may be encapsulated to form pockets, where the pockets can be affixed to the boot layer. The at least one or more individual impact pads may comprise at least one impact structure and/or at least one impact structure assembly, at least one first layer, at least one second layer, and at least one top covering or at least one bottom covering. Alternatively, the at least one or more pocketed individual impact pads may comprise an impact mitigation structure and/or at least one impact mitigation structure assembly, and a least one top covering. The at least one first layer or the at least one second layer may include a 2-way stretch material, a 4-way stretch material, a foam layer, polycarbonate layer, a hotmelt layer, boot layer and/or any combination thereof. The at least one top or at least one bottom covering may be a two- or four-way stretch fabric, where the top and bottom covering may be the same material or the at least one top and bottom covering may be different materials. The impact mitigation structure may be “free-floating” and/or fixed within the at least one top covering and/or at least one bottom covering, or permanently secured within the at least one top and/or bottom covering. The polycarbonate layer can be thin, flexible, yet substantially rigid to assist with absorption of the forces and reduce wear/tear. The foam layer can include polymeric foams, quantum foam, polyethylene foam, polyurethane foam (PU foam rubber), XPS foam, polystyrene, phenolic, memory foam (traditional, open cell, or gel), impact absorbing foam, latex rubber foam, convoluted foam (“egg create foam”), EVA foam, VN600 foam, Evlon foam, Ariaprene or Ariaprene-like material, impact hardening foam, compression foam, and/or any combination thereof. The at least one foam layer may have an open-cell structure or closed-cell structure. The foam layer can be further tailored to obtain specific characteristics, such as anti-static, breathable, conductive, hydrophilic, high-tensile, high-tear, controlled elongation, and/or any combination thereof.
In various embodiments, the one or more impact pad section(s) can comprise at least one impact structure, the at least one impact structure can comprise at least a portion of filaments, a portion of auxetic structures, a portion of zigzag structures, a portion of herringbone structures, and/or laterally supported filaments and/or wall structures. Such impact mitigation structures may include polygonal structures and/or thin, longitudinally extending members that may be shaped and configured to deform non-linearly in response to an impact force, auxetic structures, re-entrant structures, TPU cones, impact foam, and/or any combination thereof. In various instances, a non-linear deformation behavior of one or more of these structures is expected to provide improved protection against high-impact forces and/or oblique forces, as well as afford a significant level of durability, elasticity and/or flexibility to the impact pad section(s). In various embodiment, the impact pad section(s) can be deformable and/or stretchable, which can include deformability in a variety of directions, including along the cephalad/caudal, medial/lateral and/or anterior/posterior axes of the helmet and/or the wearer, as well as complex combinations thereof.
In various embodiments, the one or more impact pad sections could comprise auxetic structures and/or could comprise re-entrant shaped structures, such as bowtie shapes, and/or could comprise a series of repeating geometric shapes or undulating structures, such as T-shaped or chevron shapes, or various combinations thereof.
In various embodiments, a soft helmet design could be designed and/or tailored to accommodate various types and/or locations of forces, including factors or a combination of two or more factors in a sport-specific and/or position-specific manner, which could include impact protection features designed to protect against one or more specific locations and/or types of locations and/or degrees of impact or other forces, including (but not limited to) source of impact, angle of impact, player activity type, play type, player position, location of impact, angle of impact, severity of impact, and/or frequency of impacts.
In one embodiment, an impact mitigation structure comprises a plurality of spaced apart elongated walls, each of the plurality of elongated walls having a wall height and a undulated pattern, each of the plurality of elongated walls having a cross-sectional shape, the cross-sectional shape including a first lower portion and a second upper portion, the first lower portion comprising a base having a cross-sectional base width and a base height, the second upper portion comprising an upwardly extending longitudinal member, the upwardly extending longitudinal member extending generally perpendicular from the base and having a cross-sectional longitudinal member width and a longitudinal member height, the base width is greater than the longitudinal width and the base height is less than the longitudinal member height; and at least one support member, the at least one support member extending perpendicular from at least a portion of a length of the plurality of spaced apart elongated walls.
In one embodiment, an impact mitigation pad comprises a base material layer, the base material layer having a first surface and a second surface, a recess disposed onto a first surface extending towards the second surface; and an impact mitigation structure, the impact mitigation structure comprising a plurality of spaced apart elongated walls, the plurality of spaced apart walls disposed within the recess, the recess having a recess height, each of the plurality of elongated walls having an elongated wall height, an elongated wall width and a undulated pattern, each of the plurality of elongated walls having a cross-sectional shape.
In one embodiment, the protective helmet comprises a liner, the liner having an external surface and an internal surface; and a plurality of impact pads, at least a portion of the plurality of impact pads comprising base material layer, an impact mitigation structure, a first material layer and a second material layer, the base material layer having a first surface and a second surface, a recess disposed onto a first surface extending towards the second surface, the impact mitigation structure comprising a plurality of spaced apart elongated walls, the plurality of spaced apart walls disposed within the recess, the recess having a recess height, each of the plurality of elongated walls having an elongated wall height, an elongated wall width and a undulated pattern, each of the plurality of elongated walls having a cross-sectional shape, the plurality of impact pads being coupled to the liner external surface.
While the various optimized soft-shell helmet components and/or designs provided herein are depicted with respect to soccer and/or related sports, it should be understood that the various devices, methods and/or components may be suitable for use in protecting players in various other athletic sports, as well as law enforcement, military and/or informal training session uses. For example, the embodiments of the present invention may be suitable for use by individuals engaged in athletic activities such as football, two hand touch football, flag football, softball, dodge ball, baseball, bowling, boxing, cricket, cycling, motorcycling, golf, hockey, lacrosse, soccer, rowing, rugby, running, skating, skateboarding, skiing, snowboarding, surfing, swimming, table tennis, tennis, or volleyball, water polo, wrestling, wakeboarding and/or during training sessions related thereto.
Described herein are many specific embodiments, but these should not be construed as limitations on the scope of any inventions or of what may be claimed, but rather as descriptions of factors specific to various implementations of the present inventions. Certain factors described herein in the context of separate implementations can also be implemented in a single implementation. Conversely, various factors described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable sub combination. Furthermore, the factors as described above may be recited as acting in certain combinations and even initially claimed as such, one or more factors from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a sub combination or variation of a sub combination.
The term “soft helmet” or “soft shell” should not be limited to helmet designs that solely incorporate only soft or flexible components, but could also include helmets or other protective clothing designs that may incorporate harder and/or relatively rigid, shell or plate components or similar features, including the incorporation of flexible or sliding plates that can accommodate stretching and/or flexing of the overlying/underlying helmet structure(s).
In various embodiments, a soft helmet can comprise a headband, head wrap, cap and/or full coverage helmet having one or more impact mitigating structures disposed thereon, such as shown in
Accordingly, the boot layer or liner 50 may be constructed from a single, continuous template or using two or more templates. As shown in
In various embodiment, the impact mitigation structures can range in size or wall height 140 from 1 to 20 mm thick, and may incorporate different thicknesses of structure(s) throughout one single impact mitigation pad and/or pad assembly, and among the several impact mitigation pads and/or pad assemblies in the soft shell helmet, to desirably accommodate different frequencies, types and/or magnitudes of impact anticipated for the wearer. Such design can be sport and/or player specific, including various designs for sports such as soccer, etc.
In various additional embodiments, the impact mitigating structures may comprise filaments (longitudinally extending members that deform non-linearly in response to an impact source), polygonal structures (in an array or segmented), single-layered impact layers or multi-layered impact layers, and/or any combination thereof. Furthermore, the impact mitigating structures may be provided in a continuous array or a segmented array. The thin, longitudinally extending members may be shaped and configured to deform non-linearly in response to an impact force. The non-linear deformation behavior is expected to provide improved protection against high-impact forces, and/or oblique forces. The non-linear deformation behavior can be described by at least a portion of the filament's individual and/or en-masse stress-strain profile. The non-linear stress-strain profile can illustrate that there is an initial rapid increase in resistance to an impact force, followed by a change in slope that may be flat, decreasing or increasing slope, followed by a third region with a different slope.
If desired, the impact mitigating structures can comprise laterally supported filaments. The impact mitigating structures can comprise at least a portion of a plurality of filaments that are interconnected by laterally positioned walls or sheets in a polygonal configuration. At least a portion of the filaments arranged in a hexagonal pattern interconnected by laterally positioned walls. Alternatively, other polygonal structures known in the art may be contemplated, such as triangular, square, pentagonal, hexagonal, septagonal, octagonal, etc. A plurality of sheets or lateral walls can be secured between adjacent pairs of filaments with each filament having a pair of lateral walls attached thereto. In the disclosed embodiment, the lateral walls can be oriented approximately 120 degrees apart about the filament axis, with each lateral wall extending substantially along the longitudinal length of the filament. Alternatively, the hexagonal pattern may allow at least one lateral wall to be asymmetric, which the angle of the wall may be between 90 to 135 degrees. The shape, wall thickness or diameter, height, and configuration of the lateral walls and/or filaments may vary to “tune” or “tailor” the structures to a desired performance. For example, one embodiment of a hexagonal structure may have a tapered configuration. The hexagonal structure can have a top surface and a bottom surface, with the bottom surface perimeter (and/or bottom surface thickness/diameter of the individual elements) may be larger than the corresponding top surface perimeter (and/or individual element thickness/diameter). In another example, the hexagonal structure can have an upper ridge. The upper ridge can also facilitate connection to another structure, such as an inner surface of a helmet, an item of protective clothing, and/or a mechanical connection (e.g., a grommet or plug having an enlarged tip that is desirably slightly larger than the opening in the upper ridge of the hexagonal element).
Desirably, at least a portion of the elements in the impact mitigating structures will desirably buckle and/or deform in response to an incident force, where buckling may be characterized by a localized, sudden failure of the filament structure subjected to high compressive stress, where the actual compressive stress at the point of failure is less than the ultimate compressive stress that the material is capable of withstanding. Furthermore, the at least a portion of the filaments may be configured to deform elastically, allowing the at least a portion of the filaments to substantially return to their initial configuration once the external force is removed.
Furthermore, the polygonal or hexagonal structures may be manufactured as individual structures. The manufacturing individual polygonal or hexagonal structures may include extrusion, investment casting or injection molding process. Each individual polygonal or hexagonal structure may be affixed directly to the inner or outer surface of the helmet outer layer, inner or outer surface of the helmet inner layer, the inner or outer surface of the helmet impact absorbing layer, and/or any combination thereof. Also, they may have the same shape and configuration with repeating symmetrical arrangement or asymmetrical arrangement and/or different shape and configurations with repeating symmetrical arrangement or asymmetrical arrangement.
Conversely, the polygonal or hexagonal structures may be manufactured directly into a patterned array affixed to at least one base material. The base material may be manufactured with a polymeric or foam material. The polymeric or foam material may be elastic to allow it to be easily bent, twisted or flexed to conform to complex surfaces. Alternatively, the polymeric and/or foam material may be substantially rigid. The manufacturing of each patterned array of polygonal or hexagonal structures may include extrusion, investment casting or injection molding process. Each patterned array of polygonal or hexagonal structure and/or the base material may be affixed directly to the liner.
If desired, a regional location and/or distribution of the segmented arrays on the boot layer may be positioned to accommodate a desired “position-specific” purpose. In various embodiments, the segmented arrays may include regionally specific arrays, such as the front, jaw, midline (surrounding the majority of the circumference to include right side, mid-back and left side), top, lower back layer 1 and lower back layer 2.
The impact mitigating structures may be bonded or coupled directly to a boot layer or liner. The impact mitigating structures and the boot layer may further comprise at least one top covering and one bottom covering. The at least one top covering and at least one bottom covering may comprise a resilient fabric that may include a two-way or four-way stretch material, any elastic material, a soft-flexible material, and/or any combination thereof. The at least one top covering and at least one bottom covering may be the same material, or they may be different materials. The impact mitigating structures and the boot layer may be coupled to a foam layer or other layer. Such coupling may be accomplished by using adhesives, molding, heat and/or material welding, sintering or any other method known in the art. The foam layer may comprise a single layer or multiple layers, which any of the layers may be comprised of various types of foam, such as TPU foam, Poron XRD foam, impact resistant foam, compression foam, and/or any combination thereof. All of the segmented impact mitigating structures may be coupled to the base layer or at least a portion of the segmented impact mitigating structures may be coupled to the base layer. Alternatively, the impact mitigating structures may be “free-floating” within the base layer. The base layer can be coupled around the complete perimeter of the impact mitigating structure completely enclosing the impact mitigation structure, but still allowing the impact mitigation structure to “freely-float” and/or be fixed within the base layer. In addition, the base layer can be coupled around at least a portion of the perimeter of the impact mitigating structure leaving an opening, such that the impact mitigation structure “freely-floats” within base layer. The opening may be sized and configured to allow the impact mitigation structure to be removably coupled within the base layer, and easy replacement of the impact mitigation structure. The opening may be closed using various mechanical methods known in the art, including stitching, snaps, Velcro, magnets, and/or any combination thereof.
In various embodiments, each of the individual impact mitigating structures or patterned arrays of mitigating structures may be have at least one covering to form individual pads, pad assemblies or pad arrays. The at least one covering may be a loosely or tightly woven fabric. The fabric may be polymeric, such as polypropylene, polyethylene, polyester, nylon, PVC, PTFE, and/or any combination thereof. The fabric may be 2-way or 4-way stretch material. Furthermore, the at least one covering may be breathable and wick away moisture easily from the skin while carrying out various sporting and athletic activities. For example, the covering may completely or continually cover an entire array of impact mitigating structures (not shown). Conversely, the covering may cover at least a portion of an entire array of impact mitigating structures. Furthermore, the covering may cover segmented arrays of impact mitigating structures or individual impact mitigating structures.
In various embodiments, each of the individual impact mitigating structures or patterned array of mitigating structures may have at least one foam layer. The at least one foam layer can include polymeric foams, quantum foam, polyethylene foam, polyurethane foam (foam rubber), XPS foam, polystyrene, phenolic, memory foam (traditional, open cell, or gel), impact absorbing foam, compression foam, latex rubber foam, convoluted foam (“egg create foam”), EVA foam, VN600, Evlon foam, impact hardening foam, and/or any combination thereof. The at least one foam layer may have an open-cell structure or closed-cell structure. The at least one foam layer can be further tailored to obtain specific characteristics, such as anti-static, breathable, conductive, hydrophilic, high-tensile, high-tear, controlled elongation, and/or any combination thereof.
One particularly advantageous feature of the designs described herein is the ability to mold and/or assemble the impact layer and various other helmet components in a flat plane, which can make the tool design and construction much easier. For the best possible fit on all different head shapes, an ideal material to wrap the head with is a four way stretch material or a material that can stretch in all directions, and the impact mitigating structures can be attached to this type of a material and, due to the unique design, can flex and take shape over a complex contoured shape without wrinkles. Finally, the walled impact structure allows for an impact protective layer that easily allows for moisture vapor to pass thru, allowing the users head to naturally cool when wearing, unlike other impact layers that limit this ability.
For example,
Accordingly, the boot layer or liner 230 may form a seam 270, the seam 270 may be formed through a heat press, ultrasonic welding or vibration welding techniques to surround the perimeter of the boot liner 230. The foam layer can include polymeric foams, quantum foam, polyethylene foam, polyurethane foam (PU foam rubber), XPS foam, polystyrene, phenolic, memory foam (traditional, open cell, or gel), impact absorbing foam, compression foam, latex rubber foam, convoluted foam (“egg create foam”), EVA foam, VN 600 foam, Evlon foam, Ariaprene or Ariaprene-like material, impact hardening foam, and/or any combination thereof. The at least one foam layer may have an open-cell structure or closed-cell structure. The foam layer can be further tailored to obtain specific characteristics, such as anti-static, breathable, conductive, hydrophilic, high-tensile, high-tear, controlled elongation, and/or any combination thereof.
As best seen in
In various embodiments, the impact mitigation structures can incorporate varying offsets (i.e., array thickness as measured in a perpendicular direction outward from the surface of the wearer's head), including offsets of 4 to 6 millimeters, 7 to 9 millimeters and/or 11 to 13 millimeters. The soft helmets can be provided in a variety of sizes (3 sizes, in at least one example), with each size desirably accommodating a range of head sizes, with overlap between each member of each range.
In various embodiments, the overall thickness of the soft helmet could be 8 millimeters or less, which is a significant improvement over competitive designs that can be 15 to 20 millimeters or more in thickness.
The one or more individual impact pads or individual impact pad assemblies may permanently and/or removably affixed or coupled to the at least one boot layer or liner and regionally placed around the player's head for enhanced protection. The one or more individual impact pads and/or impact pad assemblies may be desirably positioned on different regions of the head, including the frontal section, top or ridge section, lower back, mid-back, left side and front side, temples, jaw region and/or any combination thereof. For example,
Accordingly, the front pad assembly 1100 with the back pad assembly 1150 must be affixed or coupled together to create the soft shell helmet 1180 as shown in
The plurality of impact mitigation pads 1390 may comprise an impact pad assembly. The impact pad assembly comprises an impact mitigation pad 990, a first material layer 1070, a second material layer 1080 as shown in
Alternatively, the plurality of impact pads 1390 may comprise a first material layer or base material layer having a first surface and a second surface, a recess disposed onto a first surface extending towards the second surface, the recess having a recess height; and an impact mitigation structure, the impact mitigation structure comprising a plurality of spaced apart elongated walls, the plurality of spaced apart walls disposed within the recess, the recess having a recess height, each of the plurality of elongated walls having a height, a width and a undulated pattern, each of the plurality of elongated walls having a cross-sectional shape.
Each of the plurality of elongated walls or a plurality of elongated walls may comprise a uniform height, width and undulated pattern. Alternatively, each of the plurality of elongated walls or a plurality of elongated walls may comprise a non-uniform height, width and undulated pattern. The elongated wall height may comprise a range between 6 mm to 1.2 cm. The undulated pattern may be may comprise herringbone shape 880, chevron shape 890, a zig zag shape 900, and/or any combination thereof as shown in
In addition, the elongated wall height may be a high-aspect ratio structure. If the length is greater than the width, a high aspect ratio structure, the impact mitigation structure 1370 can be more prone to buckling, the buckling being a sudden lateral deflection away from the longitudinal axis of the elongated walls. The aspect ratio may be between 3:1 to 1,000:1, where the length is greater than the width. The cross-sectional shape may comprise a solid or hollow shape. The longitudinal member may comprise a conical or frustum shaped structure, but it also may comprise a square, cylinder, triangle, shaped structure. The elongated walls may also undergo elastic deformation, allowing the elongated walls to return to its initial configuration after an impact. The first or base material layer 1070 and/or the second material layer 1080 may comprise a 2-way stretch material, a 4-way stretch material, a polymer or polycarbonate material, and/or a foam layer. The foam layer can include polymeric foams, quantum foam, polyethylene foam, polyurethane foam (PU foam rubber), XPS foam, polystyrene, phenolic, memory foam (traditional, open cell, or gel), impact absorbing foam, latex rubber foam, convoluted foam (“egg create foam”), EVA foam, VN600 foam, Evlon foam, Ariaprene or Ariaprene-like material, impact hardening foam, compression foam, and/or any combination thereof. The at least one foam layer may have an open-cell structure or closed-cell structure. The foam layer can be further tailored to obtain specific characteristics, such as anti-static, breathable, conductive, hydrophilic, high-tensile, high-tear, controlled elongation, and/or any combination thereof.
In various embodiments, the outer surface of the soft helmet can externally expose the various voids within the impact absorbing structures, which could significantly improve ventilation, wicking and/or cooling of the helmet and the player beneath (see
In various alternative embodiments, some portion of the impact mitigation structures may have an outer covering, including outer coverings in some regions of the soft helmet and with no outer coverings in other regions of the soft helmet.
In various embodiments, a soft helmet could include a ridge, dome or peak section that covers the top of the wearer's head. This could include one or more impact absorbing structures and related components to protect the top of the wearer's head. The peak section could cover the entire top of the wearer's head, or some portions thereof, depending upon user desire and comfort. The dome or peak section may be removably coupled or permanently integrated. The dome or peak section may be removably coupled using methods known in the art, such as stitching, Velcro (hook & loop), snaps, magnets, and/or any combination thereof.
In at least one exemplary embodiment, a soft helmet could comprise a head band or sweat band structure 800, 1190, 1200 for encircling at least a portion of the wearer's head, with the band incorporating at least one impact mitigating structure therein and/or thereupon (see
The headband 800, 1190, 1200 may have different standard sizes. Such standard sizes may include, small, medium, large, xlarge, etc. The sizes can have a width or circumference of 40 to 70 cm. The first material 1220 and the second material 1230 may comprise TLC AP, with a 65 C shore hardness, a 2-way stretch, and/or a 4-way stretch. The impact mitigation structure 1250 can be a portion of filaments, a portion of laterally supported filaments, auxetic structures, undulating structures, and/or any combination thereof. The headband may comprise a rear seam 1300 and/or a side internal stitch or seam 1240.
In at least one exemplary embodiment, a “soft” shell helmet can include a protective headband. The protective headband may comprise a tubular or generally cylindrical shape and configuration, which desirably fits around the circumference of an upper portion of the wearer's head (i.e., across the forehead and above a portion of the ears and potentially covering the mid-back region). The soft-shell helmet headband may comprise at least one first layer, at least one second layer, and/or at least one impact mitigation structure or impact mitigation structure assembly as shown in
The at least one first layer or the at least one second layer may be one or more of the following: a foam layer, polycarbonate layer, two- or four-way stretch fabric (e.g. Lycra), a hotmelt layer, boot layer and/or any combination thereof. The at least one first layer or at least one second layer may be the same material or may be different materials. The polycarbonate layer can be thin, flexible, yet substantially rigid to assist with absorption of the forces and reduce wear/tear. The foam layer can include polymeric foams, quantum foam, polyethylene foam, polyurethane foam (PU foam rubber), XPS foam, polystyrene, phenolic, memory foam (traditional, open cell, or gel), impact absorbing foam, latex rubber foam, convoluted foam (“egg create foam”), EVA foam, VN600 foam, Evlon foam, Ariaprene or Ariaprene-like material, impact hardening foam, and/or any combination thereof. The at least one foam layer may have an open-cell structure or closed-cell structure. The foam layer can be further tailored to obtain specific characteristics, such as anti-static, breathable, conductive, hydrophilic, high-tensile, high-tear, controlled elongation, and/or any combination thereof, and may be 0.5 mm to 3 mm thick, and 45-60 cm in diameter. The at least one top covering may be a two- or four-way stretch fabric that may be standard sized and/or a custom sized. The custom sized style fabric (see
In addition, the wall height and/or the longitudinal member height may be a high-aspect ratio structure. If the length is greater than the width, a high aspect ratio structure, the impact mitigation structure 1370 can be more prone to buckling, the buckling being a sudden lateral deflection away from the longitudinal axis of the elongated walls. The aspect ratio may be between 3:1 to 1,000:1, where the length is greater than the width. The cross-sectional shape may comprise a solid or hollow shape. The longitudinal member may comprise a conical or frustum shaped structure, but it also may comprise a square, cylinder, triangle, shaped structure. The elongated walls may comprise herringbone shape 880, chevron shape 890, a zig zag shape 900, and/or any combination thereof as shown in
Furthermore, the at least a first material 1350 and a second material 1360 may comprise a foam layer or foam material, a 2-way stretch material and/or a 4-way stretch material. The at least a first material 1350 and a second material 1360 may comprise different materials or the same materials. In addition, the at least a first material 1350 and a second material 1360 may further comprise a coating or laminate that is disposed on an interior surface or an exterior surface of the at least a first material 1350 and a second material 1360. Such coating or laminate may comprise a flexible fabric or a urethane. The at least a first material 1350 and a second material 1360 may further comprise one or more ventilation holes 1365, where the one or more ventilation holes 1365 may extend from the first material 1350 through the second material 1360, and/or the one or more ventilation holes 1365 may extend a portion from the first material 1350 towards the second material 1350. The foam layer can include polymeric foams, quantum foam, polyethylene foam, polyurethane foam (PU foam rubber), XPS foam, polystyrene, phenolic, memory foam (traditional, open cell, or gel), impact absorbing foam, latex rubber foam, convoluted foam (“egg create foam”), EVA foam, VN600 foam, Evlon foam, Ariaprene or Ariaprene-like material, impact hardening foam, compression foam, and/or any combination thereof. The at least one foam layer may have an open-cell structure or closed-cell structure. The foam layer can be further tailored to obtain specific characteristics, such as anti-static, breathable, conductive, hydrophilic, high-tensile, high-tear, controlled elongation, and/or any combination thereof.
In various embodiments, the soft helmet could incorporate auxiliary protection features, such as ear caps or other relative more rigid structures, which could comprise modular components for addition to the helmet if desired. As best seen in
In another exemplary embodiment, the soft-shell helmet may comprise a chin-strap buckle. The chin-strap may be integrated with the boot layer and/or as a separate, independent feature that may be removably coupled. If the separate, independent chin-strap is removably coupled, the soft-shell helmet may include a through hole where a chin strap may be affixed and a buckle to allow adjustability. Alternatively, if the chin-strap is integrated with the boot layer, the chin-strap would be designed with elasticity to allow the player's chin to stretch the chin-strap to accommodate the different “chin” size and configurations. Such chin-straps can help support and/or retain the soft-shell helmet on the head of the wearer. The chin-strip may be manufactured using an elastic material and may include impact mitigation pads or other impact mitigation structures affixed to the chin-strap, if desired.
In another embodiment, the soft helmet may comprise a visor, eyewear and/or eye shields. The visor may be removably connected/coupled or integrated within the soft helmet. Such removable connections may include magnets, buckles, elastic bands, Velcro, snaps, quick release mechanism, friction, and/or any combination thereof. The visor may be manufactured with a polymer that has specific material characteristics to enhance or protect optical viewing. For example, such characteristics may include a shatterproof material, an anti-fog coating, anti-glare coating, anti-scratch coating, an anti-reflective coating, photochromic coating, tinting, UV coating, prescription based, and/or any combination thereof. The visor may be substantially flexible and curved to allow insertion under the soft helmet. The soft helmet may have a specific visor opening, where the visor may be positioned. The visor having a flange surrounding the perimeter may be disposed within the visor opening, the soft helmet inner surface may hold the flange of the visor in place. Alternatively, the visor may have mechanical connections that allow the visor to be removably connected to the external surface of the soft helmet.
If desired, a soft helmet could also provide an enhanced “underlayer” of protection within an existing protective helmet, such as within a hard, rigid or substantially rigid shell helmet. In essence, the soft helmet could be worn as a “skull cap” within the shell helmet, and provide additional impact protection thereto.
In at least one alternative embodiment, a soft helmet may comprise a cylindrical/round cap or latticed framework or similar arrangement, that could allow for various designs and/or configurations of impact absorbing structures to be added and/or removed from the helmet structure, depending upon player preference. For example, the latticed framework may comprise a hook and loop fastener surface, that attaches to corresponding surfaces on the impact absorbing structures. This could include the placement of impact mitigations structures in desired locations/arrangements to accommodate sport specific and/or position specific impact needs, including the use of impact protective elements that are modular and/or segmented structures that can be affixed to the exterior and/or interior of the soft helmet to achieve a desired helmet.
The entire disclosure of each of the publications, patent documents, and other references referred to herein is incorporated herein by reference in its entirety for all purposes to the same extent as if each individual source were individually denoted as being incorporated by reference.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The foregoing embodiments are therefore to be considered in all respects illustrative rather than limiting on the invention described herein. The scope of the invention is thus intended to include all changes that come within the meaning and range of equivalency of the descriptions provided herein.
Many of the aspects and advantages of the present invention may be more clearly understood and appreciated by reference to the accompanying drawings. The accompanying drawings are incorporated herein and form a part of the specification, illustrating embodiments of the present invention and together with the description, disclose the principles of the invention.
Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, it will be readily apparent to those of ordinary skill in the art in light of the teachings of this invention that certain changes and modifications may be made thereto without departing from the spirit or scope of the disclosure herein.
This application claims the priority of Patent Cooperation Treaty Application Serial No. PCT/US2019/025450, entitled “Protective Helmet,” filed Apr. 2, 2019 which claims benefit from Prov. Appl. No. 62/735,580 entitled “Soft Shell Helmet,” filed Sep. 24, 2018, and Prov. Appl. No. 62/651,338 entitled “Soft Shell Helmet, filed on Apr. 2, 2018, the disclosures of which are each incorporated by reference herein in their entireties.
| Number | Date | Country | |
|---|---|---|---|
| 62735580 | Sep 2018 | US | |
| 62651338 | Apr 2018 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/US2019/025450 | Apr 2019 | US |
| Child | 17062121 | US |
