Patent Application
20150257471
The present invention relates generally to the field of protective padding for use in helmets, and in particular to a new and useful single-layer padding assembly for use in various helmet types, including sports helmets. The invention is also directed to a helmet-and-padding system.
U.S. Pat. No. 6,443,513 to Glance teaches an energy absorbing device which is formed of natural or synthetic resin material or composite material, wherein energy absorption is provided by a plurality of cup-shaped cells having a thin-walled construction with a circular cross section. The absorber is specified as useful for automotive bumper impact, but the specification adds that it is also for other applications, including general cushion applications.
U.S. Pat. No. 6,923,494 to Shuler et al. teaches an energy absorber incorporated into a front bumper system on automotive vehicles. It includes a unitary molded glass mat of thermoplastic material having a plurality of outwardly extending crushable lobes. The energy absorber is combined with a fascia and a reinforcing beam with the energy absorber interdisposed to form a bumper system for automotive vehicles.
U.S. Pat. No. 7,866,716 to Perucca et al. teaches an energy absorber for a vehicle bumper system which includes multiple crush boxes that are configured to absorb impact energy. Each of the crush boxes is generally hollow and has a front wall and a plurality of side walls integrally formed with and extending from the front wall to a rear of the energy absorber.
U.S. Pat. No. 7,404,593 to Cormier teaches a modular energy absorber that is tunable. It includes one or more energy absorbing modules. The energy absorbing modules have means for coordinating energy absorbing units of the one or more modules. The absorber also has a crushable member that has an upper perimeter, a lower perimeter and an intermediate wall extending therebetween. It also includes a number (m) of breaches defined therein before impact.
U.S. Pat. No. 7,673,351 to Copeland et al. teaches a shock absorbing structure comprising a generally planar surface made of a flexible plastic material. A plurality of upstanding, hollow support members extends from the planar surface. The support members are made of flexible plastic material. There is also a plurality of openings in each of the support members, the openings define air passages within the shock absorbing structure to allow air to flow through the support members. The shock absorbing structure may be used in helmets.
A need remains for further advancements in the field of helmet padding design, in particular for a helmet padding system which provides optimal protection for the head of the wearer without adding excess weight. There also remains a need for a padding system which is inexpensive to manufacture and install in a sports helmet, relative to existing padding systems, which typically involve excessive materials and assembly steps to achieve maximal protection.
Accordingly one of the various objects of the invention is to provide a padding system that provides significant protection without adding undue weight
It is also an object of the present invention to provide an impact-absorbing padding, which is made of a single-layer thermoplastic polyurethane (TPU) sheet. The sheet has a bottom side and a top side. The bottom side is flat, and the top side is also flat and has multiple, spaced apart projections. The projections are frustaconal in shape, having a flat top side and an open bottom. The sheet has multiple holes located in the sheet equidistant from all adjacent projections.
Another object of the invention is to provide a padding which, in use, is positioned on the inside of a protective helmet shell such that the flat bottom side faces the wearer's head. A comfort liner may be used between the bottom side of the padding and the wearer's head.
The projections are also connected to one another by ribs. The ribs are continuous with the top side of the flat sheet and extend up the projection to a point partyway between the bottom of the projection and its top. In certain portions of the padding, there are four ribs to each projection. In other portions, there are fewer than four ribs to a projection. Some of the projections are free-standing, having no ribs attached to them.
The proposed padding system is also provided with a U-shaped portion, which is for facilitating securement of an inflatable liner system. In preferred embodiment, this U-shaped portion is in a crown padding region, but it is within the scope of the invention for it to be in any convenient region of the padding system.
The present invention is also directed a helmet-and-padding assembly, namely a sports helmet assembly with variable-rigidity in selected areas of the helmet to improve the impact attenuating characteristics of the helmet, while maintaining the most comfort for the wearer.
In the helmet-and-padding assembly, the padding is hardest at the region, just above edge of the front side of the helmet and becomes softer as it goes up, with the crown padding being softer than the front pad.
In certain embodiments, this variable rigidity is achieved by providing more numerous ribs in the forehead area and/or providing taller ribs in the forehead area for higher rigidity. Lesser rigidity is achieved by decreasing the height and number of ribs upwards along the pad toward the crown.
The side pads are softer than the front and crown pads, having shorter ribs and, in certain embodiments, no ribs at all.
Thus, an object of the present invention is to achieve a variable-hardness padding assembly while maintaining a uniform the thickness of the TPU material throughout the system. This provides a significant cost advantage, by reducing the cost of the injection molding process. According the invention the durometer of the TPU material is preferably, but not limited to the range of 75-Shore-A to 115-Shore-A. The durometer of the TPU is more preferably in the range of 85-Shore-A to 105-Shore-A. The durometer of the TPU is more preferably in the range of 90-Shore-A to 100-Shore-A.
A still further object of the invention is to provide a sports helmet with padding system that is fastened to the inside surface of the shell using mechanical fasteners that extend through the shell, preferably in the form of T-nuts or similar mechanical fasteners at strategic locations in the helmet shell, rather than the hook-and-loop tapes typically used for this purpose. This greatly improves ease of assembly of the padding system in the helmet shell initially, and expedites replacing the padding system that is performed as part of the reconditioning of a sports helmet, for example, before the start of each new season.
At least one of the projections has openings or slits near the top of the projection, along its sides, as well as an opening at the top. The openings on the sides and the top are oriented so that they may accommodate a male T-nut (for connecting to a helmet). The openings are oriented so that the top of a male T-nut inserted into the projection would protrude from the top of the projection and the corners of the base of the T-nut would protrude from the openings/slits along the side of the T-nut.
In certain embodiments, in place of the single-layer side padding and back padding, there is provided a dilatant cushioning. The dilatant cushioning is a shear-thickening material.
The present padding system may be employed in a helmet for football, lacrosse, baseball, softball, or any sports. The present padding system may be, as well, employed in any helmet, including helmets for non-sports contexts. It is well within the scope of the invention for the padding system to employed outside the context of helmets altogether, including, but not limited to, any situation in which impact absorption or attenuation is desired.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
Referring now to the drawings, in which like reference numerals are used to refer to the same or similar elements,
Returning to
As shown in
As shown in
As best shown in
Each projection 42 has an open, larger diameter base 42b at the top side of the sheet 42a from which it extends, a smaller diameter peak 42c, and a side wall 42d that tapers from the base 42b to the peak 42c for each projection, each base 42b, side wall 42d and peak 42c being molded of one piece of TPU with the top side of the sheet 42a from which they extend. Upon an impact on the outer surface of the helmet shell 10 and a resulting relative movement of the helmet shell 10 with respect to the head of the wearer, the small diameter peaks 42c in the areas of the impact, collapse to dissipate the impact with reduced pressure on the head of the wearer.
In the front portion 14, crown portion 16 and side portions 18, the diameter of the larger diameter base 42b is in the range of 0.3200 inches to 1.080 inches. In more preferred embodiments, the diameter of the larger diameter base 42b is in the range of 0.3600 inches to 0.9900 inches. In most preferred embodiments, the diameter of the larger diameter base 42b is in the range of 0.4000 inches to 0.9000 inches.
In the front portion 14, crown portion 16 and side portions 18, the diameter of the small diameter peak 42c is in the range of 0.2000 inches to 1.0800 inches. In more preferred embodiments, the diameter of the small diameter peak 42c is in the range of 0.2250 inches to 0.9900 inches. In most preferred embodiments, the diameter of the small diameter peak 42c is in the range of 0.2500 inches to 0.9000 inches.
In the jaw pads 70, the diameter of the larger diameter base 42b is in the range of 0.1500 inches to 0.3000 inches. In more preferred embodiments, the diameter of the larger diameter base 42b is in the range of 0.1688 inches to 0.2750 inches. In most preferred embodiments, the diameter of the larger diameter base 42b is in the range of 0.1875 inches to 0.2500 inches.
In the jaw pads 70, the diameter of the small diameter peak 42c is in the range of 0.2000 inches to 0.3600 inches. In more preferred embodiments, the diameter of the small diameter peak 42c is in the range of 0.2250 inches to 0.3300 inches. In most preferred embodiments, the diameter of the small diameter peak 42c is in the range of 0.2500 inches to 0.3000 inches.
As discussed above, the present padding system may be employed in a helmet for football, lacrosse, baseball, softball, among other sports.
In the football helmet padding system, the large diameter base 42b has a diameter in the range of 0.4000 inches to 0.9000 inches. The diameter of the small diameter peak 42c is in the range of 0.2500 inches to 0.5000 inches.
In the lacrosse helmet padding system, the large diameter base 42b has a diameter in the range of 0.5000 inches to 0.7500 inches. The diameter of the small diameter peak 42c is in the range of 0.6250 inches to 0.9000 inches.
In the baseball helmet padding system, the large diameter base 42b has a diameter in the range of 0.1875 inches to 0.2500 inches. The diameter of the small diameter peak 42c is in the range of 0.2500 inches to 0.3000 inches.
In certain embodiments, the thickness of the side wall 42d is in the range of 0.0250 inches and 0.0750 inches. In more preferred embodiments, the thickness of the side wall 42d is in the range of 0.0300 inches and 0.0650 inches. In most preferred embodiments, the thickness of the side wall 42d is in the range of 0.0350 inches and 0.0600 inches.
In certain embodiments, the height of the projections 42 is in the range of about 0.1000 inches to about 1.8000 inches. In more preferred embodiments, the height of the projections 42 is in the range of about 0.1500 inches to about 1.6500 inches. In most preferred embodiments, the height of the projections 42 is in the range of about 0.1700 inches to about 1.500 inches.
In football helmet padding system embodiments, the height of the projections 42 is in the range of about 0.5000 inches to about 1.5000 inches, in certain embodiments. In more preferred embodiments, the height of the projections 42 is in the range of about 0.55 inches to about 1.3750 inches. In most preferred embodiments, the height of the projections 42 is in the range of about 0.6250 inches to about 1.2500 inches.
In lacrosse helmet padding system embodiments, the height of the projections 42 is in the range of about 0.10 inches to about 1.2 inches, in certain embodiments. In more preferred embodiments, the height of the projections 42 is in the range of about 0.15 inches to about 1.1 inches. In most preferred embodiments, the height of the projections 42 is in the range of about 0.1875 inches to about 1.0 inches.
In baseball and softball padding system embodiments, the height of the projections 42 is in the range of about 0.2000 inches to about 0.6000 inches, in certain embodiments. In more preferred embodiments, the height of the projections 42 is in the range of about 0.2250 inches to about 0.5500 inches. In most preferred embodiments, the height of the projections 42 is in the range of about 0.2500 inches to about 0.5000 inches.
The front pad 32, crown pad 34 and back pad 38 are provided with ribs 44, each of the ribs 44 being continuous with the top side of the sheet 42a and extending up along the side wall 42d of at least one projection to a point at least partyway between an edge of the top end of the projection 42 and the top side of the sheet 42a.
It is within the scope of the invention for the variation in hardness to be achieved by adding more ribs 44 or providing taller ribs 44 in the bottom of the front pad 32 and reducing the height and number of ribs 44 between the projections moving up the padding system 12 towards the crown pad 34.
In certain embodiments, the height of the smallest rib 44 in a particular pad is about 20% of the height of the tallest rib 44. In certain embodiments, the height of the smallest rib 44 in a particular pad is about 50% of the height of the tallest rib 44. In certain embodiments, the height of the smallest rib 44 in a particular pad is about 75% of the height of the tallest rib 44. In certain embodiments, the height ribs 44 in a particular pad are about the same.
It is also within the scope of the invention to change the hardness from bottom to top by changing the density of projections 42 per unit area. In preferred embodiments, the thickness of the TPU material is uniform within a particular pad, which provides an advantage in that it allows for production by a simple injection-molding process. However, it is well within the scope of the invention to vary the durometer within a particular pad. In preferred embodiments, the durometer of the material is in the range of about 75 Shore-A to about 115-Shore-A. The durometer of the TPU is more preferably in the range of about 85-Shore-A to about 105-Shore-A. The durometer of the TPU is more preferably in the range of about 90-Shore-A to about 100-Shore-A.
The padding is hardest at the region which covers the bottom of forehead, just above edge of the front side of the helmet and becomes softer as it goes up, with the crown padding 34 being softer than the front pad 32 and having a uniform rigidity.
The side pads 36 are softer than the front 32 and crown pads 34, having shorter ribs 44 having no ribs in certain embodiments.
As illustrated in
According to the invention and contrary to current practice in the assembly of sports helmets, at least some of the pads of the padding system 12 are removably attached to the inside surface of shell by mechanical fasteners 50 extending through the shell 12, such as T-nuts shown for example in
At least some of the pads have one or more keyholes 52 therein, each keyhole, as best shown in
As with the use of mechanical fasteners to removably connect the padding system 12 to the helmet shell, the use of keyholes 52 and buttons facilitates the removable connection of the liners to the padding system 12 without the use of hook-and-loop fasteners that cannot be placed with great precision nor can they be engaged with great precision. These improved mounting arrangements improve the initial assembly and all later reconditioning of the helmet over what has been the norm in the field.
Referring now to
The liners that are over at least some of the pads have one or more resilient buttons 54 each with a resilient stem 56, formed with or fused to an outer plastic sheet of the liners, for engaging each respective keyhole 52, each button 54 having a diameter for being received in a respective large diameter portion 52a of a keyhole 52 and each stem having a diameter that is larger than the constricted passage 52c and of a size for being received in a respective small diameter portion 52b of a respective keyhole 52, so that each button 54 is removably trapped at a respective keyhole 52. As shown in
To help further connect the front liner 62 to and over the front pad 32, and as shown in
Each of the liners comprises inner and outer plastic sheets 68a, 68b made of thin (e.g. 0.02 to 0.04 inches) TPU sheets (see
The back cushion assembly 68 (
The front liner 62 as shown in
The liners also comprise at least one relatively thin foam member 62e between the inner and outer plastic sheets 62f, 62g and under the relatively thick members 62a in some of the pockets that is made of the softer foam.
The sealed plastic sheets 62f, 62g for creating the pockets of the crown liner 64 and lateral liner 66, can be inflated with air via inflating fittings 64b and 68e connected to the outer sheets of the crown liner 64 and the lateral liner 66, 68 for adding air into at least some of the pockets of the crown liner 64 and lateral liner 66 for creating a closer fit for the comfort liner assembly and the wearer's head. To this end and as shown in
The inflating fittings 64b and 68e extend in recesses in the upper edge of the back pad 38 and in the back edge of the crown pad 34 seen in
With reference to
The dilatant cushioning is of a type that its material components, in an undisturbed state-that is, before impact-flow freely when moved slowly, but on shock (such as from an impact to the outside of a helmet during a sporting event), lock together to absorb and disperse energy, before instantly returning to a flexible state. This characteristic provides protection, as well as material flexibility. It also provides both comfort to the wearer during “normal” conditions (e.g., game play where no impact is being experienced). Thus the dilatant cushioning 90, 92 quickly turns a hard state on impact, but returns to the flexible, more comfortable state immediately after the sudden shock or impact force has been removed.
Thus, counter to what is customary or typical in padding systems, the greater the force of the impact , the more the molecules lock together and the greater the protection. Therefore, the stress vs. strain characteristics are dependent on the rate of loading. In practice, this means that the harder the impact, the greater the resistance to the force.
An advantage of this material is that it provides significantly-improved impact absorption characteristics over cushioning materials that are currently employed in the art. For example, 3 mm thereof has been found to transmit 57% less force than 10 mm of EVA, despite being 60% thinner. In these embodiments, 6 mm of the material decreases the transmitted force by 79% compared with 10 mm of EVA.
Another advantage is that this material is of a type that is fully-effective and stable in a wide range of temperature environments, an important feature for helmets, whether for sports or other applications, in which heat is generated within the helmet due to long contact with a wearer's head. Depending on the work or recreational environment in which the helmet is being employed, there may be significant amounts of heat supplied from the outside environment, as well.
With reference to
The back pad 88 is provided on its bottom with foam padding 98 which may be removably attached to the back pad 88 by hook and loop fasteners. In certain embodiments, this foam padding 98 is molded EVA. As can be seen in
This embodiment also includes a pair of jaw pads 100 connected to the inner surface of the helmet by mechanical fasteners 50 extending through the helmet 80, such as T-nuts, in the manner discussed with respect to previous embodiments. The jaw pads 100 also have a foam padding 110 removably attached to their back sides. In certain embodiments, this foam padding 110 is molded EVA.
In the lacrosse helmet embodiment, the front pad 82 is comprised of a plurality of pockets containing a stiff foam for maximal protection.
As with the previous embodiments, the side pads 86 are softer than the crown pad 84 and back pad 88, and in certain embodiments, have no ribs.
As shown in
Although
In all of the embodiments discussed above, the single-layer padding system 12 is preferably of the type produced by injection molding. However, it is well within the scope of the invention for the single layer padding system 12 to be produced by any method known in the field, including, but in no way limited to, thermoforming or, any type of thermoforming, including vacuum forming.
While a specific embodiment of the invention has 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. Thus, all the features of all the embodiments disclosed herein are interchangeable so that any element of any embodiment may be applied to any of the embodiments taught herein.
