Abstract: A sports helmet kit has a shell, attachable face guard, composite helmet liner, and fit pods to improve and customize the fit of the helmet to the wearer. The composite liner consists of a base liner and a selected group of fit elements, for example, fit pods, removably attached to the inner surface of the base liner (i.e., the surface of the base liner facing the wearer's head). The fit pods are selected from a set of fit pods having different properties, for example, different sizes, thicknesses, densities, and cross-sections. The selection of fit pods from the set may be aided by taking anatomical measurements of the wearer's head and analyzing the measurements with respect to the geometry of the helmet to produce a pressure map. The measurements may be taken by physical contact or by non-contact means. The fit pods may be selected to optimize a pressure map, and thus optimize the fit, for a given wearer of the helmet.

Abstract: A football helmet comprises a plastic shell having a recess formed in the shell, a shock absorbing pad in the recess and removably connected to the shell, and a floating shell plate removably attached to the shock absorbing pad and further connected to the shell by a tab-slot engagement. The helmet may further comprise an inner liner comprising a shock absorbing element, an inflatable liner element, and a mobility layer disposed between the shock absorbing element and the inflatable liner element, the mobility layer having a plurality of raised elements formed therein to separate the shock absorbing element from the mobility layer thereby forming a gap between the shock absorbing element and the mobility layer, enabling relative movement of the inflatable liner with respect to shock absorbing element.

Abstract: A sports helmet kit has a shell, attachable face guard, composite helmet liner, and fit pods to improve and customize the fit of the helmet to the wearer. The composite liner consists of a base liner and a selected group of fit elements, for example, fit pods, removably attached to the inner surface of the base liner (i.e., the surface of the base liner facing the wearer's head). The fit pods are selected from a set of fit pods having different properties, for example, different sizes, thicknesses, densities, and cross-sections. The selection of fit pods from the set may be aided by taking anatomical measurements of the wearer's head and analyzing the measurements with respect to the geometry of the helmet to produce a pressure map. The measurements may be taken by physical contact or by non-contact means. The fit pods may be selected to optimize a pressure map, and thus optimize the fit, for a given wearer of the helmet.

Abstract: A sports helmet has composite helmet liner to improve and customize the fit of the helmet to the wearer. The composite liner consists of a base liner and a selected group of fit elements, for example, fit pods, removably attached to the inner surface of the base liner (i.e., the surface of the base liner facing the wearer's head). The fit pods are selected from a set of fit pods having different properties, for example, different sizes, thicknesses, densities, and cross-sections. The selection of fit pods from the set may be aided by taking anatomical measurements of the wearer's head and analyzing the measurements with respect to the geometry of the helmet to produce a pressure map. The measurements may be taken by physical contact or by non-contact means. The fit pods may be selected to optimize a pressure map, and thus optimize the fit, for a given wearer of the helmet.

Abstract: A protective jaw pad for a sports helmet having a shell with at least one side area for covering at least part of the jaw of a wearer, the jaw pad including a first resilient shock absorbing member of thermoplastic polyurethane, the first member having a sheet portion with multiple hollow protrusions, tapering side walls of the protrusions extending substantially to an inside surface of the side area of the shell and being compressible for absorbing shocks applied to the shell. The pad includes a second resilient shock absorbing member. A plastic cover is removably attached to the first resilient shock absorbing member, and encases the second shock absorbing member. The plastic cover and the first shock-absorbing member are releasably attached by a hook and loop fastener. The first shock absorbing member has multiple slots for receiving a T-nut at a variety of locations therealong.

Abstract: A NOCSAE-certified football helmet having a shell, internal padding attached to an inner surface of the shell, and a face guard attachable to the shell, is configured and designed to have a Predictive Concussion Incidence below 1.90, or 0.75 plus or minus 0.25, or in the range of 0.50 to 1.90, as measured by the 2018 Adult Football STAR Methodology. The face guard is attached to the shell at a plurality of attachment points below a line constructed through the midpoint of the height of the helmet and has an upper portion which contacts the shell above the face opening, without being attached to the shell at that point. The internal padding includes a front pad attached within the shell above the face opening, defining a first zone of a first stiffness and, adjacent to and above the first zone, a second zone of a second stiffness lower than the first stiffness. The internal padding also includes helmet liners which are not inflatable, and which contain slow response microcellular polyurethane pads.

Abstract: A NOCSAE-certified football helmet having a plastic shell, internal padding attached to an inner surface of the shell, and a face guard attached to the shell, is configured and designed to have a Predictive Concussion Incidence below 1.90, or 0.75 plus or minus 0.25, or in the range of 0.50 to 1.90, as measured by the 2018 Adult Football STAR Methodology. The face guard is attached to the shell at a plurality of attachment points below a line constructed through the midpoint of the height of the helmet and has an upper portion which contacts the shell above the face opening, without being attached to the shell at that point. The internal padding includes a front pad attached within the shell above the face opening, defining a first zone of a first stiffness and, adjacent to and above the first zone, a second zone of a second stiffness lower than the first stiffness. The internal padding also includes helmet liners which are not inflatable, and which contain slow response microcellular polyurethane pads.

Abstract: A sports helmet (for example a football helmet, lacrosse helmet, hockey helmet, or baseball helmet), has an inflatable liner which includes an integrated, finger-operable air pump. The liner further includes an integrated, finger-operable deflation valve that is separate from the air pump. The pump and deflation valve are operable by respective features which protrude through holes in the helmet shell, which enables the wearer of the helmet to conveniently operate the liner by inflating or deflating it as desired, without any external assistance or accessories.

Abstract: A catcher's mask comprises a two-piece plastic shell composed of a rigid front shell and a rigid rear shell. The front and rear shells are connected by a strap harness attached to the front shell and have padding assemblies. The front shell has ventilation holes including ear holes positioned over the wearer's ears and a full jaw protector integrally formed as part of front shell. A wire faceguard is removably attached to the front shell extending over the ear holes. A top upper member of the faceguard comprises a center bar part, a left side bar part bent upwardly with respect to the center bar part to form a left eyebrow area, and a right side bar part bent upwardly with respect to the center bar part to form a right eyebrow area.

Abstract: A lacrosse helmet with a plastic shell has a full jaw protector attached to the shell at a right side of the shell and at a left side of the shell, extending forwardly from the shell and extending continuously from the right side of the shell to the left side of the shell and adapted to cover and protect a lower jaw of the wearer. A faceguard made of a grid of horizontal wire members, vertical wire members, and a bottom wire member is removably attached to both the shell and the full jaw protector by loop straps. T-intersections are formed by the bottom wire member and certain of the vertical wire members, adjacent to and above the full jaw protector and forward of loop straps connecting the faceguard to the jaw protector. The loop straps act as stops against rearward movement of the vertical wire members thereby resisting the tendency of the faceguard to slide and twist when struck with blows during sports play.

Abstract: A sports helmet has composite helmet liner to improve and customize the fit of the helmet to the wearer. The composite liner consists of a base liner and a selected group of fit elements, for example, fit pods, removably attached to the inner surface of the base liner (i.e., the surface of the base liner facing the wearer's head). The fit pods are selected from a set of fit pods having different properties, for example, different sizes, thicknesses, densities, and cross-sections. The selection of fit pods from the set may be aided by taking anatomical measurements of the wearer's head and analyzing the measurements with respect to the geometry of the helmet to produce a pressure map. The measurements may be taken by physical contact or by non-contact means. The fit pods may be selected to optimize a pressure map, and thus optimize the fit, for a given wearer of the helmet.

Abstract: A sports helmet comprises a single-piece plastic shell, an occipital shock absorber attached to the inner surface of the shell in the rear region to at least partially overlie an occipital area of the head, an inflatable occipital pad removably attached to the inner surface of the shell in the rear region and positioned between the inner surface of the shell and the lateral padding assembly to push the occipital shock absorber forward when the occipital pad is inflated. The occipital pad comprises a top sheet and a bottom sheet bonded together, a plurality of inflatable pockets formed in the top sheet and fluidly connected through channels formed in the top sheet, a valve assembly for inflating the plurality of inflatable pockets, the valve assembly bonded to the bottom sheet. The valve assembly extends through a hole in the shell for inflation.

Abstract: A liner assembly for a protective helmet has a rigid shell with an inner surface and concave curvature having a front portion, a rear portion, a crown portion, a pair of opposite portions and a pair of opposite jaw flaps; a wrap-around pad has a plurality of circular cells spaced along a curved line around the inner surface, and at least one additional cell at each end of the curved line. Two jaw pads, each jaw pad removably engaged to a respective one of the jaw flaps, and each jaw pad has one cell having one cell with two curvilinear segments. Each cell of the wrap around pad and the jaw pads includes an outer sheet of thermoplastic and an inner sheet of thermoplastic.

Abstract: A catcher's mask comprises a two-piece plastic shell composed of a rigid front shell and a rigid rear shell. The front and rear shells are connected by a strap harness attached to the front shell and have padding assemblies. The front shell has ventilation holes including ear holes positioned over the wearer's ears and a full jaw protector integrally formed as part of front shell. A wire faceguard is removably attached to the front shell extending over the ear holes. A top upper member of the faceguard comprises a center bar part, a left side bar part bent upwardly with respect to the center bar part to form a left eyebrow area, and a right side bar part bent upwardly with respect to the center bar part to form a right eyebrow area.

Abstract: A football helmet has a rigid plastic football helmet shell with a raised plateau of the shell extending from the front portion, over the crown portion, toward the back portion. This raised plateau is the only raised plateau of the shell which begins in the front portion, extends over the crown portion, and ends in the back portion. The raised plateau has a left border and a right border. The left border is composed of a plurality of segments and extends continuously from the front portion, over the crown portion, toward the back portion. The segments of the left border including at least a first segment and second segment, which meet to form an angle. A non-circular first ventilation hole through the shell has at least a first side, a second side, and a third side, and is positioned at the angle, such that the first side is adjacent to the first segment and the second side is adjacent to the second segment.

Abstract: A football helmet has a rigid plastic football helmet shell with a raised plateau of the shell extending from the front portion, over the crown portion, toward the back portion. This raised plateau is the only raised plateau of the shell which begins in the front portion, extends over the crown portion, and ends in the back portion. The raised plateau has a left border and a right border. The left border is composed of a plurality of segments and extends continuously from the front portion, over the crown portion, toward the back portion. The segments of the left border including at least a first segment and second segment, which meet to form an angle. A non-circular first ventilation hole through the shell has at least a first side, a second side, and a third side, and is positioned at the angle, such that the first side is adjacent to the first segment and the second side is adjacent to the second segment.

Abstract: A NOCSAE-certified football helmet having a plastic shell, internal padding attached to an inner surface of the shell, and a face guard attached to the shell, is configured and designed to have a Predictive Concussion Incidence below 1.90, or 0.75 plus or minus 0.25, or in the range of 0.50 to 1.90, as measured by the 2018 Adult Football STAR Methodology. The face guard is attached to the shell at a plurality of attachment points below a line constructed through the midpoint of the height of the helmet and has an upper portion which contacts the shell above the face opening, without being attached to the shell at that point. The internal padding includes a front pad attached within the shell above the face opening, defining a first zone of a first stiffness and, adjacent to and above the first zone, a second zone of a second stiffness lower than the first stiffness. The internal padding also includes helmet liners which are not inflatable, and which contain Poron pads.