HELMET COMPRISING INTEGRATED ROTATIONAL IMPACT ATTENUATION AND FIT SYSTEM
A helmet can include an energy absorbing shell including an outer surface and an inner surface opposite the outer surface. A fit system member can be coupled to a rear of the energy absorbing shell to adjust a fit of the helmet for a user. A sliding layer can include an outer sliding layer surface oriented towards the inner surface of the energy absorbing shell and an inner sliding layer surface opposite the outer surface. The sliding layer can include at least one attachment member and at least one integrated fit system arm. The at least one integrated fit system arm can be coupled to the fit system member. An elastomeric member can include a first end coupled to the energy absorbing shell and a second end coupled to the attachment member of the sliding layer. Comfort padding can be coupled to the inner surface of the Sliding layer.
This application claims the benefit of U.S. provisional patent application 62/347,053, filed Jun. 7, 2016 titled “Integrated Rotational Impact Attenuation and Fit System,” the entirety of the disclosure of which is hereby incorporated by this reference.
TECHNICAL FIELDThis disclosure relates to a protective helmet comprising an integrated rotational impact attenuation and fit system and method of forming the same.
BACKGROUNDProtective headgear and helmets have been used in a wide variety of applications and across a number of industries including sports, athletics, construction, mining, military defense, and others, to prevent damage to a user's head and brain. Damage and injury to a user can be prevented or reduced by helmets that prevent hard objects or sharp objects from directly contacting the user's head. Damage and injury to a user can also be prevented or reduced by helmets that absorb, distribute, or otherwise manage energy of an impact.
SUMMARYA need exists for an improved helmet. Accordingly, in an aspect, a helmet can comprise an energy absorbing shell comprising an outer surface and an inner surface opposite the outer surface. A fit system member can be coupled to a rear of the energy absorbing shell and adjustable to fit the helmet for a user. A sliding layer can comprise an outer sliding layer surface oriented towards the inner surface of the energy absorbing shell and an inner sliding layer surface opposite the outer sliding layer surface. The sliding layer can comprise at least one attachment member and at least one integrated fit system arm. The at least one integrated fit system arm can be coupled to the fit system member. An elastomeric member can comprise a first end coupled to the energy absorbing shell and a second end coupled to the at least one attachment member of the sliding layer. Comfort padding coupled to the inner surface of the sliding layer.
The helmet can further comprise the comfort padding being disposed over the second end of the elastomeric member and the at least one attachment member of the sliding layer. The at least one attachment member of the sliding layer can be formed as an opening in the sliding layer, the second end of the elastomeric member can be disposed within the opening in the sliding layer, and the first end of the elastomeric member can be coupled to the energy absorbing shell with a pin. Helmet straps can be coupled to the energy absorbing shell and threaded through the fit system member. A second sliding layer can be disposed between the outer surface of the sliding layer and the outer surface of the energy absorbing shell. The sliding layer can be injection molded. The fit system member can be formed as a fit system cradle comprising a pinion, and the at least one integrated fit system arm can comprise a first fit system arm and a second fit system arm, the first fit system arm comprising teeth contacting a first side of the pinion and a the second fit system arm comprising teeth contacting a second side of the pinion.
In another aspect, a helmet can comprise an energy absorbing shell comprising an outer surface and an inner surface opposite the outer surface. A fit system member can be disposed inward of the energy absorbing shell and adjustable to adjust a fit of the helmet. A sliding layer can comprise an outer sliding layer surface oriented towards the inner surface of the energy absorbing shell and an inner sliding layer surface opposite the outer surface. The sliding layer can comprise an attachment member and at least one fit system arm. The at least one fit system arm can be coupled to the fit system member. An elastomeric member can comprise a first end coupled to the energy absorbing shell and a second end coupled to the attachment member of the sliding layer.
The helmet can further comprise the attachment member of the sliding layer being formed as an opening in the sliding layer, the second end of the elastomeric member being disposed within the opening in the sliding layer, and the first end of the elastomeric member being coupled to the energy absorbing shell. Helmet straps can be coupled to the energy absorbing shell and threaded through the fit system member. A second sliding layer can be disposed between the outer surface of the sliding layer and the outer surface of the energy absorbing shell. The sliding layer can be injection molded. The fit system member can be formed as a fit system cradle comprising a pinion, and the at least one integrated fit system arm can comprise a first fit system arm and a second fit system arm, the first fit system arm comprising teeth contacting a first side of the pinion and a the second fit system arm comprising teeth contacting a second side of the pinion. The fit system cradle can be coupled to the energy absorbing shell with a pin.
In another aspect, the helmet can further comprise an energy absorbing shell comprising an outer surface and an inner surface opposite the outer surface. A fit system member can be disposed inward of the energy absorbing shell. A sliding layer comprising at least one fit system arm can be coupled to the fit system member. An elastomeric member can be coupled to the energy absorbing shell and the sliding layer.
The helmet can further comprise the comfort padding being disposed over where the elastomeric member is coupled to the sliding layer. The sliding layer can comprise an opening disposed in the sliding layer, the elastomeric member can comprise a second end disposed within the opening in the sliding layer, and the elastomeric member can comprise a first end coupled to the energy absorbing shell with a pin. A second sliding layer can be disposed between the outer surface of the sliding layer and the outer surface of the energy absorbing shell. The fit system member can be formed as a fit system cradle comprising a pinion, and the at least one integrated fit system arm can comprise a first fit system arm and a second fit system arm, the first fit system arm comprising teeth contacting a first side of the pinion and a the second fit system arm comprising teeth contacting a second side of the pinion. The sliding layer can be formed with injection molding.
This disclosure, its aspects and implementations, are not limited to the specific helmet or material types, or other system component examples, or methods disclosed herein. Many additional components, manufacturing and assembly procedures known in the art consistent with helmet manufacture are contemplated for use with particular implementations from this disclosure. Accordingly, for example, although particular protective helmets are disclosed, such protective helmets and implementing components may comprise any shape, size, style, type, model, version, measurement, concentration, material, quantity, and/or the like as is known in the art for such protective helmets and implementing components, consistent with the intended operation of a protective helmet.
The word “exemplary,” “example,” or various forms thereof are used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” or as an “example” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Furthermore, examples are provided solely for purposes of clarity and understanding and are not meant to limit or restrict the disclosed subject matter or relevant portions of this disclosure in any manner. It is to be appreciated that a myriad of additional or alternate examples of varying scope could have been presented, but have been omitted for purposes of brevity.
While this disclosure includes a number of embodiments in many different forms, there is shown in the drawings and will herein be described in detail, particular embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principles of the disclosed methods and systems, and is not intended to limit the broad aspect of the disclosed concepts to the embodiments illustrated.
The disclosure presents a device, apparatus, system, and method for providing a protective helmet 30 comprising an integrated rotational impact attenuation and fit system 70, as will be discussed with respect to the figures. The helmet 30 can comprise vents or openings 32 in the helmet 30 and an energy absorbing shell 40.
The vents 32 can be formed in, and extend through, a portion or entirety of the helmet 30, including the energy absorbing shell 40. The vents 32 can allow for airflow and circulation of air from outside the helmet 30 into the helmet 30 and adjacent the head of the user to cool the user and provide ventilation.
The energy absorbing shell 40 can optionally comprise an outer shell 42 and can be formed of energy management or energy-absorbing layers or materials 44, such as foam, which are discussed in greater detail below. The protective helmet 30 can be a bike helmet used for mountain biking or road cycling, or a helmet that can be used for other applications and in other industries that also use protective headwear. In any event, the protective helmet 30 can function to provide protection while minimizing interference with an activity.
The outer shell 42 can, without limitation, be formed of a plastic, resin, fiber, or other suitable material including polycarbonate (PC), polyethylene terephthalate (PET), acrylonitrile butadiene styrene (ABS), polyethylene (PE), polyvinyl chloride (PVC), vinyl nitrile (VN), fiberglass, carbon fiber, or other similar material. The outer shell 42 can be stamped, in-molded, injection molded, vacuum formed, or formed by another suitable process. The outer shell 42 can provide a shell into which the energy management layer 44 can be disposed, whether the helmet 30 be a hard shell helmet or a soft shell helmet, as known in the art. The outer shell 42 can also provide a smooth aerodynamic finish, a decorative finish, or both, for improved performance, improved aesthetics, or both. As a non-limiting example, the outer shell 42 can comprise PC shell that is in-molded in the form of a vacuum formed sheet, or is attached to the energy management layer 44 with, e.g., an adhesive. The outer shell 42 can also be permanently or releasably coupled to the energy management layer 44, using any suitable chemical or mechanical fastener or attachment device or substance including without limitation, an adhesive, permanent adhesive, pressure sensitive adhesive (PSA), foam-core adhesive, tape, two-sided tape, mounting foam adhesive, fastener, clip, cleat, cutout, tab, snap, rivet, hog ring, or hook and loop fasteners.
The energy absorbing shell 40 can comprise an outer surface 48 of the energy absorbing shell 40 (which can also be an outer surface of the outer shell 42, when the outer shell 42 is present) that can be oriented away from the user. The energy absorbing shell 40 can further comprise and an inner surface 46 opposite the outer surface 48, which can be oriented towards a head of the user. The energy management layer 44 can be made or formed of plastic, polymer, foam, or other suitable energy-absorbing material or impact liner to absorb, deflect, attenuate or otherwise manage energy and to contribute to energy management for protecting a wearer during impacts. The energy management layer 44 can include, without limitation, expanded polystyrene (EPS), expanded polypropylene (EPP), expanded polyurethane (EPU), expanded polyolefin (EPO), or other suitable material. An in-molded helmet 30 can be formed with the outer shell 42 of the helmet being bonded directly to the energy management layer 44, and by expanding foam or the energy management layer 44 into the outer shell 42. As such, the energy management layer 44 can, in some embodiments, be in-molded into outer shell 42, as single monolithic body of energy management material 44. Alternatively, in other embodiments the energy management layer 44 can be formed of multiple, or a plurality, of portions or layers. In any event, the energy management layers 44 can absorb or manage energy from an impact by bending, flexing, crushing, or cracking.
The energy absorbing shell 40 (including the outer shell 42 and the energy management material 44) can comprise a thickness measured in a radial direction extending from a center of the helmet 30 to the outer surface 48 of the energy absorbing shell 40, the thickness being measured from an inner surface 46 to the outer surface 48. The distance of the thickness can be in a range of 5-50 mm, 5-25 mm, or 8-15 mm.
The helmet 30 can also comprise straps or webbing 60 that can be attached to the helmet 30 and can be used to couple or releasably attach the helmet 30 to the head of the user. The straps 60 can comprise a rear portion or strap 62, a front portion or strap 64, a left portion or strap 66, and a right portion or strap 68. While the various portions 62, 64, 66, and 68 of strap 62 can be portions of one or more single continuous straps, the portions 62, 64, 66, and 68 of the strap 60 can also be separate, distinct, or discrete segments of strap. In either event, the portions 62, 64, 66, and 68 of the strap 60 can be coupled or joined together mechanically or chemically, including by sewing, by being threaded through strap adjustors or clips, or by any other suitable method.
The sliding layer 100 can comprise at least one attachment member, attachment anchor, or attachment opening 106 for being coupled to an elastomeric member 120, as shown and discussed in greater detail, e.g., with respect to
The sliding layer 100 can also comprise at least one integrated fit system arm108, such as a first or left integrated fit system arm 108a and a second or right integrated fit system arm 108b. The at least one integrated fit system arm 108 can be coupled to a fit system member or cradle 80, as shown an described in greater detail in
The sliding layer 100 can be formed of a plastic, resin, fiber, metal, or other suitable low friction material or low friction coated material including nylon, polypropylene (PP), Polyoxymethylene (POM), PC, PET, ABS, PE, PVC, VN, fiberglass, carbon fiber, steel, aluminum, or other similar material or material suitable for injection molding. The outer shell 42 can be stamped, in-molded, injection molded, vacuum formed, or formed by another suitable process. In some instances a single step process like injection molding can be used, and in others a multistep process, such as vacuum forming a shape followed by cutting a feature, such as a gear rack. When the sliding layer 100 is formed by an injection molding process, the sliding layer 100 will be made of a suitable plastic for injection molding an such as nylon, or other suitable materials. The material selected for sliding layer 100 can also be selected based on its performance and suitability in the sizing or adjusting the size of the sliding layer 100 to match a size, shape, or both of the user. For example, nylon can work well not only with an injection molding process, but can also work well for forming integrated fit system arms 108 that can serve as rear racks used as part of a rack and pinion design for an sliding layer fit system 70 used to adjust to fit a size of the user's head. When selecting a size of the sliding layer 100, a general size of the sliding layer 100 should correspond to a specific size range of a size of the helmet 30 and a size of the user head, whether, e.g., small, medium, or large, so that only small adjustments are needed with the fit system 70 to provide final sizing or fine tuning of sizing to the user's head. Small differences in sizing of the fit system 70 can be understood to be sizes or adjustments that vary by percent difference of 0-20%, 0-10%, or 0-5% from a size of the user's head.
In addition to forming the sliding layers 100 in an injection molding process, vacuum molding or other suitable molding or forming process can also be used to form the sliding layer 100 as part of the fit system 70, whether or not the sliding layer 100 is formed as an integral or unitary piece of the fit system 70. As such, the sliding layer 100 can comprise arms 108 or other features or portions that are separately formed and added to the sliding layer 100 so that when the sliding layer 100 is assembled as part of the fit system 70, the composite sliding layer 100 can then acts as both an energy management feature, such as for rotation management, and a sizing feature, such as adjusting a size of the sliding layer 100 to match or correspond to a size of the head of the user. In some instances, a diameter of the sliding layer 100, as well as a height or effective height adjustment for the helmet wearer can also controlled by adjusting the sliding layer 100 as part of the fit system 70, such that all size adjustment of the helmet, including all height adjustment could be completely integrated or combined with adjustments to a size and shape of the sliding layer 100, which is further described below.
While
Adjustment and performance of the sliding layer fit system 70 can be facilitated or advanced by forming the sliding layer 100 of nylon with injection molding, allowing for the fit system arms 108 to be formed at a same time as, and as part of, the sliding layer 100, which can interact with the pinion 90 of the fit system 80. Forming the sliding layer 100 of nylon with injection molding differs from conventional or normal vacuum molded sliding layer parts or layers that have been formed and used as for rotational energy management independent of the fitting process and a fit system. By forming fit system arms 108 as part of the sliding layer 100, an integrated sliding layer fit system 70 can be achieved, which improves helmet fit, user comfort, and can improve helmet performance with respect to energy management, while simplifying construction and decreasing cost. Performance of the helmet 30 can be improved by combining the Sliding layer and the fit system, the two components being joined or integrated to provide a more stable fit for the helmet wearer as the wearer puts on the helmet, adjusts helmet straps, takes the helmet off, or wears or conveys the helmet. To the contrary, previous systems have not used a sliding layer for actual fitting, but have instead relied on two separate systems or components, an sliding layer component and a separate and distinct fit system. In the present case, the foam or main body of the helmet, which can be embodied in energy absorbing shell 40, can float outside of the sliding layer fit system 70, suspended by deformable elastomer connections 120 or other suitable connections.
As shown in
The pin 126 can be formed of plastic, metal, wood, fiber, or any other suitably strong and inexpensive material. The pin 126 can comprise any suitable or advantageous shape for remaining coupled, or directly attached, to the energy absorbing shell 40 and to the elastomeric member 120 during impacts of the helmet 30. As such, the pin 126 can remain coupled to the energy absorbing shell 40 while the elastomeric member 120 stretches and deforms, thereby allowing the sliding layer 100 to slip, slide, or move relative to the energy absorbing shell 40. As a non-limiting example, the pin 126 can comprise a shape that is elongate with a flat first end, and a rounded or ball shaped end on a second end opposite the first end.
The second end 124 of the elastomeric member 120 can be opposite the first end 122. The second end 124 can be shaped or formed to be mateably coupled, or directly attached, to one or more of the openings 106 in the sliding layer 100. The second end 124 can optionally comprise a hooked or bent end 124 that can be disposed within the opening 106 in the sliding layer 100. In other instances, the attachment member 106 of the sliding layer 100 can be a slot, clip, flange, hook, knob, protrusion, or other suitable physical structure to which the second end 124 of the elastomeric member 120 can be coupled. In other instances, the second end 124 can be chemically, thermally, or otherwise joined to the sliding layer 100, such as with another pin 126 or other intermediate structure or substance.
Conventional helmet systems with sliding layers have been limited to separate, discrete, or independent fit systems and sliding layers, such as to one or more of vacuum molded and trimmed sliding layers. The integrated sliding layer 100 and fit system 80 or integrated sliding layer fit system 70 described herein allows for the sliding layer 100 to be part of, and work seamlessly with, the fit system assembly 80. The integrated sliding layer and fit system 70 can provide improved comfort to the user through a better fit, as well as by simplifying a design of the helmet 30—by reducing a number of parts included within the helmet 30. In some instances, a better fit of the sliding layer 100 can also improve energy management performance by increasing rotation between the sliding layer 100 and the outer portion of the main helmet 30, such as energy absorbing layer 40, and decreasing rotation between the user's head and the sliding layer 100.
Thus, the integrated rotational impact attenuation and fit system 70 can comprise one or more sliding layers 100 that can be directly connected to, and interact with, a fit system member or fit system cradle 80 for sizing the helmet 30 to a head of the helmet wearer. In other words, the sliding layer 100 or portions thereof, such as the fit system arms 108, can be coupled to, or part of, the sizing of the helmet 30. Use of sliding layers 100 within a helmet 30 to assist in energy management, such as during collisions, can be achieved by facilitating rotational movement, and providing energy management through rotational movement within the helmet 30 and relative to the user's head. In addition to the rotational movement and energy management provided by the sliding layers 100, the helmet 30 can also facilitate other types of movement and energy management, such as translational movement, and as such, rotational energy management is included by way of example and not by limitation.
Where the above examples, embodiments and implementations reference examples, it should be understood by those of ordinary skill in the art that other helmet and manufacturing devices and examples could be intermixed or substituted with those provided. In places where the description above refers to particular embodiments of helmets and customization methods, it should be readily apparent that such components may be comprised of any shape, size, style, type, model, version, class, grade, measurement, concentration, material, weight, quantity, and/or the like consistent with the intended purpose, method and/or system of implementation and a number of modifications may be made without departing from the spirit thereof and that these embodiments and implementations may be applied to other to helmet customization technologies as well. Accordingly, the disclosed subject matter is intended to embrace all such alterations, modifications, and variations that fall within the spirit and scope of the disclosure and the knowledge of one of ordinary skill in the art, together with all changes that come within the meaning of, and range of equivalency of, the claims. The presently disclosed embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.
Claims
1. A helmet, comprising:
- an energy absorbing shell comprising an outer surface and an inner surface opposite the outer surface;
- a fit system member coupled to a rear of the energy absorbing shell and adjustable to fit the helmet for a user;
- a sliding layer comprising an outer sliding layer surface oriented towards the inner surface of the energy absorbing shell and an inner sliding layer surface opposite the outer sliding layer surface, the sliding layer comprising at least one attachment member and at least one integrated fit system arm, wherein the at least one integrated fit system arm is coupled to the fit system member;
- an elastomeric member comprising a first end coupled to the energy absorbing shell and a second end coupled to the at least one attachment member of the sliding layer; and
- comfort padding coupled to the inner surface of the sliding layer.
2. The helmet of claim 1, wherein the comfort padding is disposed over the second end of the elastomeric member and the at least one attachment member of the sliding layer.
3. The helmet of claim 1, wherein:
- the at least one attachment member of the sliding layer is formed as an opening in the sliding layer;
- the second end of the elastomeric member is disposed within the opening in the sliding layer; and
- the first end of the elastomeric member is coupled to the energy absorbing shell with a pin.
4. The helmet of claim 1, further comprising helmet straps coupled to the energy absorbing shell and threaded through the fit system member.
5. The helmet of claim 1, further comprising a second sliding layer disposed between the outer surface of the sliding layer and the outer surface of the energy absorbing shell.
6. The helmet of claim 1, wherein the sliding layer is injection molded.
7. The helmet of claim 1, wherein:
- the fit system member is formed as a fit system cradle comprising a pinion; and
- the at least one integrated fit system arm comprises a first fit system arm and a second fit system arm, the first fit system arm comprising teeth contacting a first side of the pinion and a the second fit system arm comprising teeth contacting a second side of the pinion.
8. A helmet, comprising:
- an energy absorbing shell comprising an outer surface and an inner surface opposite the outer surface;
- a fit system member disposed inward of the energy absorbing shell and adjustable to adjust a fit of the helmet;
- a sliding layer comprising an outer sliding layer surface oriented towards the inner surface of the energy absorbing shell and an inner sliding layer surface opposite the outer surface, the sliding layer comprising an attachment member and at least one fit system arm, wherein the at least one fit system arm is coupled to the fit system member; and
- an elastomeric member comprising a first end coupled to the energy absorbing shell and a second end coupled to the attachment member of the sliding layer.
9. The helmet of claim 8, wherein:
- the attachment member of the sliding layer is formed as an opening in the sliding layer;
- the second end of the elastomeric member is disposed within the opening in the sliding layer; and
- the first end of the elastomeric member is coupled to the energy absorbing shell.
10. The helmet of claim 8, further comprising helmet straps coupled to the energy absorbing shell and threaded through the fit system member.
11. The helmet of claim 8, further comprising a second sliding layer disposed between the outer surface of the sliding layer and the outer surface of the energy absorbing shell.
12. The helmet of claim 8, wherein the sliding layer is injection molded.
13. The helmet of claim 1, wherein:
- the fit system member is formed as a fit system cradle comprising a pinion; and
- the at least one integrated fit system arm comprises a first fit system arm and a second fit system arm, the first fit system arm comprising teeth contacting a first side of the pinion and a the second fit system arm comprising teeth contacting a second side of the pinion.
14. The helmet of claim 8, wherein the fit system cradle is coupled to the energy absorbing shell with a pin.
15. A helmet, comprising:
- an energy absorbing shell comprising an outer surface and an inner surface opposite the outer surface;
- a fit system member disposed inward of the energy absorbing shell;
- a sliding layer comprising at least one fit system arm coupled to the fit system member; and
- an elastomeric member coupled to the energy absorbing shell and the sliding layer.
16. The helmet of claim 15, further comprising the comfort padding disposed over where the elastomeric member is coupled to the sliding layer.
17. The helmet of claim 15, wherein:
- the sliding layer comprises an opening disposed in the sliding layer;
- the elastomeric member comprises a second end disposed within the opening in the sliding layer; and
- the elastomeric member comprises a first end coupled to the energy absorbing shell with a pin.
18. The helmet of claim 15, further comprising a second sliding layer disposed between the outer surface of the sliding layer and the outer surface of the energy absorbing shell.
19. The helmet of claim 15, wherein:
- the fit system member is formed as a fit system cradle comprising a pinion; and
- the at least one integrated fit system arm comprises a first fit system arm and a second fit system arm, the first fit system arm comprising teeth contacting a first side of the pinion and a the second fit system arm comprising teeth contacting a second side of the pinion.
20. The helmet of claim 15, wherein the sliding layer is formed with injection molding.
Type: Application
Filed: Dec 30, 2016
Publication Date: Dec 7, 2017
Inventors: Benjamin W. Penner (Santa Cruz, CA), Hilgard N. Muller (Felton, CA), Ben D. Pritz (Santa Cruz, CA), Gregg T. Jacobsen (Santa Cruz, CA)
Application Number: 15/395,232