Helmet construction

Abstract

A shell-less helmet is provided with resilient material and a stainless steel interior member to protect the individual from head trauma while at the same time preventing the use of the helmet as a weapon due to the resilient helmet outer layer.

Description

FIELD OF THE INVENTION

This invention relates to helmet construction and more particularly to the design of a sports helmet designed to protect the head of an individual while at the same time preventing the use of the helmet as a weapon.

BACKGROUND OF THE INVENTION

The sports helmets are typically designed with an exterior hard shell and padding within the shell which is utilized to protect the head of the individual. Typically these helmets surround the head of the individual, and the individual's ears. Nonetheless there are a wide range of head injuries to athletes that occur for instance during the playing of such games as football, lacrosse, and other team sports as well as for instance injuries that occur from riding motorcycles, bicycles and the like as well as injuries that occur when skiing, snowboarding, skating or when driving a vehicle.

The injuries that can occur in such instances include simple fractures to complex dangerous conditions such as when an athlete fractures their mandibular jaw bone and has subsequent injuries to the skull's base caused by the thrust of a condylar bone part. Also of importance are concussions that can cause brain damage that result in dementia or Alzheimer's and in some cases death. Moreover there are reports of athletes that have died with the severing of a vertebral cord at the neck from the sharp edge of a helmet.

Not only are these helmets used in sporting activities, these helmets may be used as protective gear in construction and in all cases where it is desired to protect the head of the individual.

In addition to the injury of athletes, there are also the injuries due to head butting or collision of a rigid helmet with an athlete in which the helmet has a rigid outer shell. This is most notable in football in which head butting accounts for a not small percentage of the injuries, especially when the helmet comes in contact with the head of an opposing athlete. In such cases the helmet can be used as a weapon to disable or severely injure an opposing player. While head butting is outlawed in most sports, the occasional head butting with individuals wearing helmets is regularly documented as a serious cause of injury.

There is therefore a need for an improved helmet construction which better protects the head of an individual while at the same time preventing the helmet from being used as a weapon to inflict damage on one's opponents.

SUMMARY OF INVENTION

In order to provide for better protection of the head of an individual in the subject invention the helmet is a shell-less helmet in which an exceptionally strong stainless steel inner layer is sandwiched between two resilient layers that form the first helmet element. The resilient layers, which may in one embodiment be a silicone rubber layer, are provided with sufficient rigidity to resist high impact strikes due to the internally-carried sandwiched stainless steel layer. It will be appreciated that the stainless steel provides significant penetration resistance against outside forces applied to the helmet. In addition to stainless steel other rigid exceptionally strong materials having the same strength and penetration resistance may be sandwiched by the silicone rubber layers, although stainless steel provides significant penetration rejection performance.

As will be appreciated, the exterior of the helmet is made of a resilient material such that if there is contact between the helmet and another individual there will be a less severe impact to the individual, thus in large measure preventing the use of the helmet as a weapon.

On the other hand the silicone rubber stainless steel sandwich provides shock absorption and penetration resistance to which can be added an interior gel layer to the inside of the silicone rubber sandwich. Further, a foam layer can be positioned adjacent the liquid gel layer, with the foam layer cushioning the forces that reach this layer, with the foam layer in one embodiment being a NASA foam material such as NASA foam, miracle foam and viscolastic foam. This foam is very dense and conforms to a-shape. It is medium soft to soft at 3.2-4.0 lbs. Per cubic foot with a density of 2.80-4.0.

Finally, the portion of the helmet which touches the head may be in the form of a soft absorbent fabric layer that is detachable and washable for reuse.

It will be appreciated that in one embodiment the helmet is in close proximity to the head of the individual, if not in a tight press fit.

In order to provide ventilation to the head orifices at the position of the individual's ears are provided through all of the layers thus to be able to provide ventilation within the helmet adjacent the person's head. These orifices permit hearing while the helmet is in place and provide ventilation to reduce sweat surrounding the head.

Optionally miniature fans may be inserted into the aforementioned orifices for cooling purposes, whereas in another embodiment speakers and other apparatus for receiving audio commands from the outside may be placed at or around these orifices.

Also grill bars may be attached to the forward portion of the helmet to provide a face guard, whereas the helmet may be provided with neck protection gear which extends from the underside back of the helmet to protect against neck injuries.

It will be noted while the helmet includes a strong rigid stainless steel sandwich layer, in one embodiment the neck protecting layer which extends downwardly at the back of the helmet includes a resilient silicone rubber layer, liquid gel in a thick plastic bag adjacent to this resilient layer, followed by a foam layer and a detachable layer of absorbent fabric, in much the same way that the helmet is constructed.

The net result of the helmet construction is that there is improved protection of the head of the individual from blows or forces applied to the helmet in which the rigid strong stainless steel sandwich structure protects the person wearing the helmet from skull concussion and fracture, whereas the helmet is of sufficiently pliable external material so that when the helmet strikes another individual, the individual does not sustain the same type of injury as would occur with a hard plastic shelled helmet.

In summary, a shell-less helmet is provided with resilient material and a stainless steel interior member to protect the individual from head trauma while at the same time preventing the use of the helmet as a weapon due to the resilient helmet outer layer.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the subject invention will be better understood in connection with the Detailed Description, in conjunction with the Drawings, of which:

FIG. 1 is a diagrammatic illustration of the prior art in which football helmets having hard outer shells can be used as weapons during an athletic contest, with the hard outer shell resulting in head trauma and damage to an opponent due to the hard outer shell structure;

FIG. 2 is a diagrammatic illustration of the subject helmet showing a resilient outer layer and has a composite structure comprising a stainless steel layer sandwiched between two resilient rubber layers, one of which forms the outer surface of the helmet, also including additional shock absorbing padding including a gel layer, a foam layer and a fabric layer;

FIG. 3 is a cross-sectional view of the helmet of FIG. 2 illustrating the composite structure of the helmet of FIG. 2 as well as the composite structure of the neck protector portion of the helmet;

FIG. 3A is a diagrammatic illustration of the pear shaped end portion at the bottom of the stainless steel layer which is barbed and secures the bottom of the stainless steel layer to adjacent resilient layers.

FIG. 4 is a front view of the helmet of FIG. 2 showing the surrounding of an individual's head with the helmet; and,

FIG. 5 is a side view of the helmet of FIG. 2 showing an orifice in the side of the helmet running to the inside of the helmet which serves as a ventilator channel, also into which a speaker may be incorporated for transmitting sound into the interior of the helmet at the position of the individual's ears.

DETAILED DESCRIPTION

Referring now to FIG. 1, a number of players 10 and 12 are shown in a football contest in which a player 10 is carrying a football 14 and uses his helmet 16 to head butt player 12, with his helmet including a hard outer shell 18 that is typical in many sports helmets.

The problem with the hard outer shell is while it may be capable of sustaining a direct hit, it nonetheless can generate a high intensity hit against an opposing player which can cause concussions, broken bones and contusions, oftentimes resulting in injuries that are not immediately visible at the time of impact.

The reason for the safety concern lies in the fact that the hard outer shell of the helmets can be used as a weapon against opposing players; and for this reason the helmets have been a cause of concussion and other brain injuries as well as neck and torso injuries due to the non-resilient nature of the helmet itself.

In order to make the playing of sports safer and to provide a safety helmet for protecting an individual when he participates in sports and the like, a resilient protective helmet is provided as shown in FIG. 2.

Referring to FIG. 2, a helmet 20 is illustrated that has a resilient outer surface 22 which is the outer surface of a composite structure utilized to protect the individual's head. In one embodiment this outer surface is a resilient layer such as silicone rubber. The composite structure also includes a stainless steel member sandwiched between silicone rubber layers to provide the internal strength, shock absorption and resistance to high impacts, thus to prevent injury the individual using the helmet.

Note that in one embodiment the silicone rubber layers are made of SILASTIC 24020-V Nat Silicone Rubber Natural made by Dow Corning Corporation.

The stainless steel reinforcement structure sandwiched between the rubber layers is sufficient to prevent piercing injury from forces from the outside of the helmet and in one embodiment is stainless steel layer of between 5 and 7 millimeters in thickness. The steel is of the highest tensile and ultimate strength corresponding to AISI 302 cold rolled stainless steel having a yield strength of 520 MPa and an ultimate strength of 860 MPa. The silicone rubber layers into which it is sandwiched in one embodiment are one inch layers which absorb impact as does the stainless steel layer.

In one embodiment the steel layer is 304 stainless steel with a 7 mm thickness. Note that 304 stainless steel is an Austenitic Nickel Alloy, although classic 8/18 A2 stainless steel may be used.

To provide further protection for the individual interior of the sandwich structure is a liquid gel layer which resides adjacent the inner rubber layer. This gel layer is Austenitic Foam Hangzhou Phase Change Technology, Company LTD of Zaejiang Mainland China. Note a foam layer is applied exteriorly to the gel layer. This foam layer is in general provided to further absorb impacts and provides a cushioning member for the individual's head within the helmet. Finally there may be an optional fabric layer attached to the exterior of the foam layer to provide for ventilation and to absorb perspiration so that the use of the subject helmet is comfortable.

As will be seen an orifice 23 runs through the helmet and all the composite layer structure to the interior of the helmet for purposes of ventilation with the orifice ideally being adjacent the ear of the individual who is going to be using the helmet. This orifice provides the ability for the individual wearing the helmet to hear commands or other instructions from outside the helmet and in one embodiment may be provided with a speaker and a two-way radio apparatus so that instructions from the bench can be transmitted to a player. Finally the helmet may be provided with a fan in orifice 23 as will be described.

The helmet optionally is provided with a neck protector 24 which extends down from the base 26 of helmet 20 and has a similar composite structure to that of the helmet, absent the sandwiched stainless steel structure. Moreover, as can be seen, helmet 20 is provided in one embodiment with a mandibular jaw protection extension 30 which runs forwardly and provides a shield to the individual's jaw, with the extension having the same composite structure as that of the helmet. The helmet is also provided in one embodiment with a face guard 32 which may be of a resilient structure so that it itself does not form a weapon of a hard nature but rather provides a resilient, shock absorber member to protect the face of the individual wearing the helmet.

Referring now to FIG. 3, the composite structure of helmet 20 is illustrated showing the resilient outer surface 22 to be the surface of a rubber layer 32 of a sandwich of the aforementioned stainless steel layer here shown at 34 and another silicone rubber layer 36 which forms the main protective barrier close to the individual's head. It will be appreciated that the resilient outer surface 22 is not hard plastic as is the case in most athletic equipment helmets but rather is resilient so that it cannot inadvertently or advertently be used as a weapon in the athletic contest.

The stainless steel sandwich structure described above is further provided with a liquid gel layer 38 adjacent the inner surface of rubber layer 36 for shock absorbing purposes, which is in turn provided with a foam layer 40 that further absorbs any impacts to the helmet. Finally a fabric liner 42 is releasably attached to the interior surface of foam layer 40 to absorb perspiration and moisture within the helmet as well as providing a pleasing feel of the helmet when the helmet is worn by an individual. This fabric may be either a washable stretch-knit coolmax layer or a washable silk/bamboo woven quilted fabric layer, both available from Select Foam of Miami, Florida.

As shown in FIG. 3A, it will be noted that stainless steel layer 34 is held in place by pear shaped end portions 44 to keep the stainless steel from slipping around in the sandwich structure. This pear shaped end portion is made of hard silicone rubber and has outwardly projecting barbs that securely anchors the bottom end of the stainless steel layer 34 to the adjacent silicone rubber layers 32. Even when tremendous forces are exerted on the stainless steel layer and the whole helmet, the stainless steel layer will not come loose.

It will also be noted that in one embodiment that the stainless steel layer is between 5 and 7 millimeters thick, whereas the silicone rubber layers are on the order of 1 inch thick made in one embodiment by Dow Corning Corporation. Further, the liquid gel layer 38 incorporate a liquid gel within a sealed sack or a container, with the gel layer with sack being on the order of 4 mm-10 mm in thickness and is made by Dow Corning Corporation of Midlen, Mich. under the brand name Sakura Snow. Finally, the foam layer 40 is on the order of 1 inch in thickness and may be altered for instance to accommodate different size heads for helmet sizing. In one embodiment the foam is a viscolastic foam such as NASA foam manufactured by Select Foam.

It will be appreciated that the helmet of FIGS. 2 and 3 is to be worn tightly to the head of the individual wearing the helmet, with the helmet size being quickly adapted by providing different thickness foam layers to accommodate different size heads.

It will also be seen that the neck protecting extension 24 may include for instance of an outer silicone rubber layer 50 interior to which is a liquid gel layer 52 is affixed. Thereafter, a foam layer 54 is positioned interior to the gel layer so as to provide significant neck protection against a blow from outside. In the embodiment shown the neck protector does not include the sandwiched stainless steel silicone rubber layers of the helmet, as such is deemed unnecessary to protect the neck from injury.

Referring to FIG. 4, helmet 20 is shown in front view with face guard 34 positioned as illustrated and with the helmet construction having forward chin protecting portion 30 as illustrated beneath an orifice 60 in the helmet. It will be seen that when worn this helmet provides close to 360 degree head protection, with orifice 60 providing visibility for the individual wearing the helmet.

As illustrated in FIG. 5, helmet 20 is provided with orifice 22 into which is inserted a fan 62 for providing ventilation to the interior of the helmet as well as audio passage to the interior of the helmet. Alternatively, orifice 22 may be provided with a speaker and appropriate electronics to wirelessly provide instructions to the person wearing the helmet.

What is therefore provided is a helmet construction which has a resilient outer surface that prevents the helmet from being used as a weapon and further provides significant impact protection through the sandwich of a stainless steel layer between two resilient layers. Should such protection be deemed insufficient for shock absorbing, interior shock absorbing layers may include a liquid gel layer and an additional foam layer so as to provide shock absorption suitable to protect the individual wearing the helmet. Moreover, a removable fabric layer may be positioned to the interior of the composite structure so as to provide wicking of moisture away from the head of the individual while at the same time providing ventilation properties.

It will be appreciated while the subject invention has been described in terms of a contact sport such as football and for instance lacrosse and the like, the subject helmet may be utilized as a head protection device for any type of sports or commercial activity such that the helmet may be utilized for instance for bike riding or other vehicle riding, as well as providing a safety helmet for use in construction, policing and other applications.

While the present invention has been described in connection with the preferred embodiments of the various figures, it is to be understood that other similar embodiments may be used or modifications or additions may be made to the described embodiment for performing the same function of the present invention without deviating therefrom. Therefore, the present invention should not be limited to any single embodiment, but rather construed in breadth and scope in accordance with the recitation of the appended claims.

Claims

1. A shell-less helmet for protecting an individual wearing the helmet from helmet impacts, comprising:

an outer helmet member comprising a first layer of resilient material;

a stainless steel member interior to said outer helmet member to absorb helmet impact from the exterior of the helmet, and,

a foam layer interior to said stainless steel member to cushion impact from the outside of the helmet, said foam layer adapted to contact the individual wearing said helmet.

2. The helmet of claim 1, and further including a fabric liner interior to said foam layer.

3. The helmet of claim 2, wherein said fabric liner is releasably attachable to said foam layer.

4. The helmet of claim 1, and further including a second resilient layer to the interior of said stainless steel member such that said stainless steel member is sandwiched between said resilient layers.

5. The helmet of claim 1, and further including a gel layer positioned between said stainless steel member and said foam layer.

6. The helmet of claim 1, wherein said stainless steel member is an austenitic nickel alloy.

7. The helmet of claim 6, wherein said stainless steel member is 304 stainless.

8. The helmet of claim 6, wherein said stainless steel member is 8-18 A2 stainless.

9. The helmet of claim 4, wherein said resilient layers include silicone rubber layers.

10. The helmet of claim 1, and further including a rear neck extension portion extending down from the base of said helmet, said neck extension portion including a sandwich of an outer layer of silicone rubber, an inner foam layer and a gel layer sandwiched therebetween.

11. The helmet of claim 1, and further including a aperture in said helmet running through said resilient member, said stainless steel member and said foam layer providing ventilation to the interior of said helmet and providing an audio passage to the interior of said helmet.

12. The helmet of claim 11, and further including a fan in said aperture.

13. The helmet of claim 11, and further including an audio reproduction unit in said aperture.

14. The helmet of claim 4, wherein said stainless steel member has a periphery and further including an expanded shaped end at said periphery.

15. The helmet of claim 14, wherein said expanded shaped end is pear shaped and includes barbs adapted to secure the pear shaped end to adjacent resilient layers.

16. The helmet of claim 1, wherein said foam layer include viscolastic foam.

17. The helmet of claim 16, wherein said viscolastic foam includes NASA foam.

18. A method of protecting an individual from head impact comprising the step of providing the individual with a helmet having a resilient outer member, an interior stainless steel member adjacent said outer member, a resilient inner member adjacent said stainless steel member, a gel member adjacent said inner resilient member and a foam layer adjacent said gel layer, the combination of the stainless steel member sandwiched between resilient adjacent members, the gel member and the foam layer protecting the head of the individual from head impact.

19. A helmet comprising:

a resilient outer member;

an interior stainless steel member adjacent said outer member;

a resilient inner member adjacent said stainless steel member;

a gel member adjacent said inner resilient member; and,

a foam layer adjacent said gel layer, the combination of said stainless steel member sandwiched between resilient adjacent members, the gel member and the foam layer protecting the head of the individual from head impact without providing a hard outer shell.

20. Apparatus for protecting an individual from head impact comprising:

a helmet having a resilient outer member, a resilient inner member and an interior member sandwiched between said resilient outer member and said resilient inner member, said interior member having physical characteristics associated with stainless steel, the combination of said interior member sandwiched between said resilient members providing head protection without a rigid outer shell.