COLLAPSIBLE SAFETY HELMET

Abstract

A safety helmet includes an outer collapsible shell that collapses toward an inner shell when an impact force is received, and does not return toward its initial (pre-collapsed) state when the impact force is removed. The safety helmet provides improved protection against injuries.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of each of: U.S. Provisional Patent Application Ser. No. 62/087,877, filed on 5 Dec. 2014, and U.S. Provisional Patent Application Ser. No. 62/143,328, filed on 6 Apr. 2015. The co-pending Provisional Applications are hereby incorporated by reference herein in their entirety and are made a part hereof, including but not limited to those portions which specifically appear hereinafter.

FIELD OF THE INVENTION

This invention is directed to a collapsible safety helmet that can be used in sports, motorcycling, construction and other hard hat activities.

BACKGROUND OF THE INVENTION

Various helmet designs are known for improved safety and warning of possible concussions resulting from an impact. A SpeedFlex™ helmet, available from Riddell, incorporates a flexible shell that works in conjunction with padding inside the shell to help absorb impacts to the head of a wearer. This helmet is designed for football players to reduce the incidence of concussions and brain injury. Another football helmet, the Xenith X2™, available from T+B Sports, collapses upon impact by releasing air through small vent openings, and then immediately returns to its normal shape. Both helmets include a flexible shell that recovers to its original pre-collapsed configuration.

A Shockbox sensor available from Impakt Protective can be installed on a helmet and can detect the forces of impacts and send corresponding warning signals to a monitor. A sensor system called the In Site™ Impact Response System, available form Riddell, performs a similar function. These and other sensor systems detect the force of impacts and send appropriate signals, but do not reduce the incidence of brain injury.

The presently available collapsible safety helmets have a disadvantage in that the resilient materials quickly return to their normal shape, causing unnecessary shaking of the brain inside the skull. While these helmets reduce the incidence of injury, more is needed to reduce the incidence and severity of brain injuries within the skull.

SUMMARY OF THE INVENTION

The present invention is directed to an improved safety helmet for use in sports, motorcycling, construction, and other hard hat activities requiring safety gear. The helmet is designed to reduce the transfer of impact forces to the user, and thus reducing the potential for injuries.

The helmet of the invention includes an outer collapsible shell having an initial configuration for receiving an impact force, an inner shell configured to receive a head of a wearer, and a space between the inner shell and the outer collapsible shell. The outer collapsible shell is formed of a permanently collapsible material such that, upon receiving an impact force, at least a portion of the outer shell collapses by a distance toward the inner shell through the space, and does not return to the initial configuration when the impact force is removed.

By using a permanently collapsible outer shell (i.e., an outer shell formed of permanently collapsible material), the damage caused by the impact force is largely borne by the helmet, thus reducing the potential for injury to the wearer. By avoiding the use of a resilient material that snaps back to its original shape following impact, the helmet seeks to further reduce trauma.

With the foregoing in mind, it is a feature and advantage of the invention to provide an improved safety helmet that provides greater protection against impact and/or injury than conventional safety helmets.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a safety helmet of the invention.

FIG. 2 is a front view of the safety helmet, shown on a wearer.

FIG. 3 is a back view of the safety helmet of FIG. 1.

FIG. 4 is a sectional view of the safety helmet, taken along line 4-4 in FIG. 1.

FIG. 5 shows the safety helmet of FIG. 4, with the outer collapsible shell collapsed in a side region.

FIG. 6 shows the safety helmet of FIG. 4, with the outer collapsible shell collapsed in a crown region.

FIG. 7 is a top view of another embodiment of the safety helmet, with the outer collapsible shell removed.

FIG. 8 is a sectional view of the safety helmet, taken along the line 8-8 in FIG. 7.

FIG. 9 is a back view of the safety helmet of FIG. 7.

FIG. 10 schematically illustrates an embodiment of the invention in which a plurality of safety helmets is in electronic communication with a remote monitoring booth.

FIG. 11 is a sectional view of one embodiment of the safety helmet in which the space between the outer collapsible shell and the inner shell is wider in the crown region than in the two side regions.

FIG. 12 is a sectional view of one embodiment of the safety helmet in which the thickness of the outer collapsible shell is larger in the crown region than in the two side regions of the helmet.

DETAILED DESCRIPTION OF THE INVENTION

In FIGS. 1-3, a safety helmet 10 includes a front region 12, a rear region 14, a crown region 16, and two side regions 18 and 20. As shown in FIGS. 4-6, each of the regions 12, 14, 16, 18 and 20 of the safety helmet 10 is defined by an outer collapsible shell 22 for receiving an impact force, an inner shell 24 configured to receive a wearer's head 26 (FIG. 2), a space 28 between the inner shell 24 and the outer collapsible shell 22, and a padding layer 30 in the space 28 that is suitably a foam material. The helmet 10 can also include a face mask 32 for protecting the wearer's face, depending on the desired use of the helmet. Sensors 34 can be provided in each of the regions 12, 14, 16, 18 and 20 for detecting an amount of collapse of the outer shell 22 resulting from an impact, and for sending a corresponding signal to a monitor (not shown).

The outer shell 22 of the helmet 10 is permanently collapsible, meaning that it collapses toward the inner shell 24 through the space 28 upon receiving an impact force, but does not return to its initial (pre-collapse) configuration when the impact force is removed. The outer collapsible shell 22 can be formed of an inelastic collapsible polymer, a collapsible metallic foil, or another permanently collapsible material that is sturdy enough to absorb a potentially injurious impact force and flexible enough to collapse (bend) in response to the force. Suitable inelastic polymers include without limitation polypropylene, high density polyethylene, polyesters, polyamides, fluoropolymers such as polytetrafluoroethylene, and combinations thereof. Suitable metallic foils include without limitation aluminum, tin, and the like. The thickness of the collapsible outer shell 22 is also an important factor in ensuring that the outer shell 22 is sturdy enough and flexible enough to protect the wearer from otherwise injurious impact forces.

When an impact force is received, the outer shell 22 collapses into the space 28 by a collapsing distance that is less than or equal to the distance between the outer shell 24 and the inner shell 22. When the impact force is then removed, the outer collapsible shell 22 may recover only slightly or none at all. When the impact force is removed, the outer shell 22 should remain collapsed by at least 75% of the collapsing distance (meaning recovery of no more than 25%), suitably by at least 90% of the collapsing distance (meaning recovery of no more than 10%), preferably by about 100% of the collapsing distance (meaning essentially no recovery).

The inner shell 24 is suitably formed of a rigid plastic material that is strong, lightweight, and does not flex or break. Suitable rigid plastic materials include without limitation polycarbonate, polyacrylonitrile and rigid plastic foams formed of rigid polyurethane, rigid acrylic polymers, and other foamable polymers. Alternatively, many of the polymer materials used to form the collapsible outer shell 22 can be formed into thick enough layers to serve as the non-collapsible inner shell 24.

The padding layer 30 is suitably a soft foam and can be formed of flexible polyurethane, flexible acrylic polymers, cotton foam or another soft material. The padding layer 30 should be sufficiently compressible so as not to hinder the collapsing of the collapsible outer shell 22. The padding layer 30 softens the impact of the collapsible outer shell 22 against the inner shell 24 (FIGS. 5 and 6).

The safety helmet 10 can be designed with an outer collapsible shell 22 that collapses toward the inner shell 24 upon receiving an impact force in any one or more of the crown region 16, the front region 12, the rear region 14 and the side regions 18 and 20. In each case, the collapsible outer shell 22 does not return to its initial configuration in the region of impact after the impact force is removed. FIG. 5 illustrates a situation where the outer shell 22 receives an impact force in the rear region 14 and collapses toward the inner shell 24 in that region, shown by collapsed portion 36. FIG. 6 illustrates a situation where the outer shell 22 receives an impact force in the crown region 16 and collapses toward the inner shell 24 in that region, shown by collapsed portion 38. In either case, the collapse is permanent, i.e. the collapsed portion 36 or 38 does not return to the initial, pre-collapsed state when the impact force is removed.

The sensors 34 (FIGS. 1-3) can be positioned in the outer collapsible shell 22 in one or more of the regions, suitably in each of the regions 12, 14, 16, 18 and 20 of the safety helmet 10. The sensors 34 can monitor either or both of a) the amount of impact force and b) the collapsing distance of the collapsible outer shell 22, when an impact force is received, and can send corresponding signals to a monitor (not shown). The signals can then be analyzed to gauge the severity of the impact, whether or not immediate medical attention is warranted and, if so, the type of medical attention that may be needed.

FIGS. 7-9 show an alternative embodiment of the safety helmet 10 in which one or more inflated bladders 40, filled with a colored fluid (gas or liquid), are disposed in the space 28 between the collapsible outer shell 22 and the inner shell 24. When the outer collapsible shell 22 takes an impact and sufficiently collapses, the adjacent bladder 40 breaks and releases the colored fluid. The colored fluid passes through vent openings 42 (FIG. 9) in the outer shell 22 and may cause coloration of the outer surface 46 of the outer shell 22 in the vicinity of the vent openings 42 through which the colored fluid escapes.

The one or more bladders 40 can be formed of any breakable plastic material that is strong enough to contain the fluid and withstand normal use, but weak enough to break when the outer collapsible shell 22 is driven into a collapsed position by a predetermined impact force. Suitable materials include without limitation polypropylene, polyethylenes, polyurethane, polyisoprene, polybutadiene, and the like. In one embodiment, the fluid can be a colored dye that imparts a luminescent color to the affected portions of outer surface 46. The colored dye can be green, red, blue, or any distinctive color. The number and positioning of bladders 40 should be selected so that the bladder not only breaks when a predetermined impact force is received by the outer collapsible shell 16, but also signals the location of the break. If the number of bladders 40 is too small and their size is correspondingly large, then the bladders 40 will be difficult to break because the fluid will redistribute in the bladder when an impact force is received. If the number of bladders 40 is too large, and their size is correspondingly small, then too little fluid may be emitted to cause sufficient visual signaling when the bladder breaks. Suitably, the number of bladders 40 in the space 28 can be about 4 to about 20, or about 5 to about 15.

In another embodiment, the breaking of a bladder 40, and/or the sufficient collapsing of outer collapsible shell 22, will trigger the illumination of one or more lights 44 on the outer surface 46 of the outer collapsible shell 22, either in the region of impact or over a larger area. In this embodiment, the bladders 40 may or may not be filled with the colored fluid. The lights 44 can be illuminated by circuitry within the bladders 40 that is activated by the breaking of one or more bladders 40. Alternatively, the lights 44 can be illuminated by circuitry in or on the outer collapsible shell 16 that is activated by sufficient collapsing of the outer shell 22. Alternatively, the lights 44 can be activated by impact sensors 48 on or in the outer collapsible shell 22 that detect an impact force of a sufficient predetermined magnitude. In the embodiment of FIG. 8, impact sensors 48 are positioned on the inner shell 24 and would detect an impact force of sufficient magnitude to collapse the outer shell 22 to the inner shell 24. Suitably, the lights 44 are LED lights and can be strobe lights. Other types of lights can also be used.

In another embodiment, shown in FIG. 10, the information from the breaking of one or more bladders 40, and/or the collapsing of the outer shell 22 to the inner shell 24, can be transmitted from any one or more of a plurality of helmets 10 to a remove booth 50. The booth 50 can serve as a central location for monitoring potentially injury-causing impacts, and for signaling the need for medical attention. Thus, the information generated by the collapsing of the outer shell 22 and/or the breaking of one or more bladders 40 can cause any one or more of a) the generation of colored fluid through vent openings 42, b) the illumination of lights 44, and c) the transmission of a signal to a booth 50. The booth 50 may be located on the sidelines of a football field, for example, and can serve as an emergency station for the immediate treatment of an injury, or the provision of medical help and supplies to the injured player.

It is also known that certain regions of the head, such as the crown region, are more prone to impact injuries than others. The collapsible safety helmet 10 of the invention can be designed to provide extra protection in the region(s) of the head that are more prone to injury. In the embodiment of FIG. 11, the space 28 is wider in the crown region 16 compared to the side regions 18 and 20 of the helmet 10. Because the distance between the outer collapsible shell 22 and the inner shell 24 is greater in the crown region 16, the outer shell 22 is able to collapse by a greater amount in response to an impact, before reaching the inner shell 24. In the embodiment of FIG. 12, the outer collapsible shell 22 is thicker in the crown region 16 than in the two side regions 18 and 20. In both embodiments, the magnitude of the impact force required to collapse the outer shell 22 through the span 28 and to the inner shell 24 will be greater in the crown region 16 than in the side regions 18 and 20. Corresponding adjustments can also be made to provide greater impact protection in the front and/or rear regions 12 and 14 of the safety helmet 10.

While the embodiments of the invention described herein are presently preferred, various modifications and improvements can be made without departing from the spirit and scope of the invention. The scope of the invention is indicated by the appended claims, and all changes that fall within the meaning and range of equivalents are intended to be embraced therein.

Claims

1. A safety helmet, comprising:

an outer collapsible shell having an initial configuration for receiving an impact force;

an inner shell configured to receive a head of a wearer; and

a space between the inner shell and the outer collapsible shell;

wherein upon receiving an impact force, at least a portion of the outer shell collapses by a distance toward the inner shell through the space and does not return to the initial configuration when the impact force is removed.

2. The safety helmet of claim 1, wherein the outer shell remains collapsed by at least 75% of the distance when the impact force is removed.

3. The safety helmet of claim 1, wherein the outer shell remains collapsed by at 90% of the distance when the impact force is removed.

4. The safety helmet of claim 1, wherein the outer shell remains collapsed by about 100% of the distance when the impact force is removed.

5. The safety helmet of claim 1, wherein the outer shell comprises an inelastic polymer.

6. The safety helmet of claim 5, wherein the inelastic polymer is selected from the group consisting of polypropylene, high density polyethylene, polyesters, polyamides, polytetrafluoroethylene, and combinations thereof.

7. The safety helmet of claim 1, wherein the outer shell comprises a collapsible metallic foil.

8. The safety helmet of claim 1, wherein the inner shell comprises a rigid plastic material.

9. The safety helmet of claim 8, wherein the rigid plastic material is selected from the group consisting of polycarbonate, polyacrylonitrile, rigid plastic foams, and combinations thereof.

10. The safety helmet of claim 1, further comprising a foam layer between the outer collapsible shell and the inner shell.

11. The safety helmet of claim 1, wherein the helmet comprises a front region, a rear region, a crown region, two side regions and a face mask.

12. The safety helmet of claim 11, wherein the outer collapsible shell covers the front region, rear region, crown region and two side regions.

13. The safety helmet of claim 12, wherein the space between the inner shell and the outer collapsible shell and the inner shell is thicker in the crown region than in the two side regions.

14. The safety helmet of claim 12, wherein the outer collapsible shell has a thickness that is greater in the crown regions than in the two side regions.

15. The safety helmet of claim 1, further comprising vent openings in the outer collapsible shell and one or more breakable bladders in the space between the inner shell and the outer collapsible shell.

16. The safety helmet of claim 15, wherein the one or more breakable bladders contain a colored fluid.

17. The safety helmet of claim 15, further comprising one or more lights on or in the outer collapsible shell, responsive to a breaking of one or more of the breakable bladders.

18. A safety helmet, comprising:

a front region, a rear region, a crown region and two side regions;

an outer collapsible shell having an initial configuration for receiving an impact force;

an inner shell configured to receive a head of a wearer; and

a space between the inner shell and the outer collapsible shell;

wherein upon receiving an impact force in the crown region, the outer collapsible shell collapses toward the inner shell in the crown region and does not return to the initial configuration when the impact force is removed.

19. The safety helmet of claim 18, wherein upon receiving an impact force in the front region, the outer collapsible shell collapses toward the inner shell in the front region and does not return to the initial configuration in the front region when the impact force is removed.

20. The safety helmet of claim 18, where upon receiving an impact force in the rear region, the outer collapsible shell collapses toward the inner shell in the rear region and does not return to the initial configuration in the rear region when the impact force is removed.

21. The safety helmet of claim 18, wherein upon receiving an impact force in either side region, the outer collapsible shell collapses toward the inner shell in the side region and does not return to the initial configuration in the side region when the impact force is removed.

22. The safety helmet of claim 18, further comprising one or more breakable bladders in the space between the inner shell and the outer collapsible shell.

23. The safety helmet of claim 22, further comprising a colored fluid contained in the one or more breakable bladders.

24. The safety helmet of claim 22, further comprising a plurality of lights responsive to a breaking of one or more of the breakable bladders.

25. The safety helmet of claim 24, wherein the plurality of lights comprises LED lights.

26. The safety helmet of claim 24, wherein the plurality of lights comprises strobe lights.

27. A safety helmet, comprising:

an outer collapsible shell having an initial configuration for receiving an impact force;

an inner shell configured to receive a head of a wearer;

a space between the inner shell and the outer collapsible shell; and

one or more sensors for detecting a distance of collapse in the outer collapsible shell and sending a signal corresponding to the distance of collapse;

wherein upon receiving an impact force, the outer collapsible shell collapses by the distance toward the inner shell through the space and does not return to the initial configuration when the impact force is removed.

28. The safety helmet of claim 27, wherein the outer collapsible shell remains collapsed by at least 90% of the distance when the impact force is removed.

29. The safety helmet of claim 27, comprising a plurality of the sensors in different regions of the helmet.

30. The safety helmet of claim 27, further comprising a layer of padding in the space between the inner shell and the outer collapsible shell.

31. The safety helmet of claim 27, wherein the one or more sensors transmits a signal to a remote booth when the outer collapsible shell receives an impact force.