Shock Reducing Helmet

Abstract

A shock reducing helmet includes a helmet body made of an outer and inner shell, ear openings, and face shield or visor that connects flush to the helmet body. The outer shell is formed from the strongest and lightest weight materials, such as polycarbonate, or other plastics, Kevlar, carbon fiber, or metal, to provide a high strength to weight ratio and minimize fracture. The inner chamber includes shock absorbing structures made from materials such as a nickel-titanium shape-memory alloy, polycarbonate, other plastics, Kevlar, carbon fiber, or metal. Some variants have a viscous or gaseous layer around the springs to increase stability upon linear and rotational impact. The face shield or visor is made of a clear polycarbonate that connects flush with the outer shell to eliminate visibility interference and rotational injuries caused by competitors pulling the metal bars commonly present in football helmets.

Description

RELATED APPLICATIONS

This application claims priority to the U.S. Provisional Patent Application Ser. No. 62/565,079 for a “Shock Reducing Sports Helmet,” filed Sep. 28, 2017, and currently co-pending, and to the U.S.

Provisional Patent Application Ser. No. 62/730,793 for a “Shock Reducing Helmet,” filed Sep. 13, 2018, and currently co-pending, both of which are fully incorporated herein by reference.

FIELD OF THE INVENTION

The present invention pertains generally to protective equipment for use in potentially dangerous activities. More particularly, the present invention pertains to a shock reducing helmet. The present invention is particularly, but not exclusively, useful as a sports helmet worn on an athlete's head to reduce the impact and shock experienced by the user.

BACKGROUND OF THE INVENTION

For more than forty years, football helmets have retained a basic design of a plastic outer shell, interior padding, and metal bars that extend from the outer shell. Recently, the National Operating Committee on Standards for Athletic Equipment (NOCSAE) recognized that current helmet designs fail to account for significant rotational forces football players routinely encounter. Accordingly, effective in 2018, football helmets approved by NOCSAE will have to meet increased rotational safety standards.

Originally, helmets were made of leather and then transitioned to a hard outer plastic layer with minimal interior padding, which protected against skull fractures, but not concussions or other internal head trauma. This problem has been partially solved by increased padding to minimize the force of impact by decreasing the acceleration, but this increased padding only protects against linear impact, not rotational impact. An improved helmet is needed to protect against rotational impact, as the brain stem can twist during rotational collisions, causing damage to nerves.

Another problem with current helmet designs is the existence of a metal face guard that can be pulled or knocked by other players leading to rotational injuries. The metal bars can also interfere with visual fields. An improved face guard design is needed to eliminate rotational injuries caused by the current design and improve visibility.

In light of the above, it would be advantageous to provide a shock reducing sports helmet made from improved materials for the shell and core of the helmet to increase stability upon linear and rotational impact and thereby minimize head injuries.

It would be further advantageous to provide a shock reducing sports helmet designed to eliminate rotational injuries and visibility interference created by the metal bars of the face guard.

SUMMARY OF THE INVENTION

Disclosed is a shock reducing helmet having a rigid shell that encloses a shock-absorbing chamber. The rigid shell has an exterior, or “outer shell,” and an interior, or “inner shell,” with the chamber sandwiched between and enclosed by the outer shell and the inner shell. The chamber provides a shock-absorbing capability through truss elements, springs, a viscous filling, an elastic material, or any combination thereof. The “core,” or the chamber with any filling material and shock absorbing elements, is less rigid than the shell.

In a preferred embodiment, the core has a viscoelastic composite structure with at least two subcomponents. One embodiment of the composite structure has one elastic subcomponent and one viscous subcomponent. Another embodiment has two viscoelastic elements, and yet another has more than two viscoelastic elements. This structure mimics a human or animal skull in that the outer external, or exposed, structure is more rigid than the internal, or porous trabecular core, structure. Both the outer and internal structure may provide a degree of elasticity, but the inner structure is less rigid and more elastic.

A preferred embodiment of the shell has multiple perforations through which a fluid or gas may pass.

A preferred embodiment of the shock reducing helmet includes a football helmet with a lightweight polycarbonate shell, a visco-elastic core with varying density as a function of placement along the skull, and a clear, polycarbonate face shield that connects flush to the outer shell and will enclose the helmet.

The shell is formed from the strongest and lightest weight materials, such as polycarbonate, (acrylonitrile butadiene styrene) ABS plastic, or other plastics, Kevlar, carbon fiber composite, metal, or any combination thereof (such as carbon fiber reinforced polymer), to provide a high strength to weight ratio and to minimize fracture. On either side of the shell there are ear openings extending from the outer shell through the inner shell to allow for transmission of sound. On the back of the shell there is a flap attached with hook-and-loop fasteners, such as those sold under the brand name VELCRO, so it can be easily removed in the event of a neck injury or to insert cooling pads and accelerometers.

The core may include elastic or visco-elastic spring elements or features to absorb shock and may include a viscous layer filling the open chambers around the springs to slow recoil of the springs. This design increases stability upon linear and rotational impact, thereby minimizing head injuries.

The face shield is preferably made of a clear polycarbonate, such as Lexan, that connects flush with the outer shell of the helmet body to eliminate visibility interference and rotational injuries caused by knocking or pulling the metal bars of face shields used in prior art. The face shield is connected to the outer shell via fasteners on the face shield that mate with connection points on the outer shell and may include a rotating flange feature, or lip, and hook-and-loop fasteners. Vents are located at the front of the face shield to allow for air flow.

In an alternative embodiment, the core includes steel springs with perforated chambers between the springs that mimic trabeculae of spongy bone to allow for gas exchange to dampen the spring load upon impact.

In an alternative embodiment, the core is formed from a thin, super elastic alloy to absorb shock and a viscous layer to dampen the force of impact.

In an alternative embodiment, the core includes hollow perforations that mimic trabeculae found in trabecular cancellous bone, also known as spongy bone to allow for gas exchange to dampen the force of impact.

Preferred embodiments of a shock reducing sports helmet of the present invention include a craniomaxillofacial impaction absorbing system assembly composed of a monolithic anisotropic shell, modular fit liner, modular facemask, and modular cervical protector. Air vent features in the shell, liner, facemask, and cervical protector improve ergonomics by reduced weight and increased airflow.

The shell subcomponent has an outer, (superior-lateral), and inner, (inferior-medial), contiguous semi-rigid shell wall enclosing a dampening viscoelastic porous core and elastic compression springs (where present) which serve to decelerate, dampen, and dissipate impact energy imparted to the user's head which in turn mitigates the occurrence of concussive injury by reducing intracranial motion of the brain. Viscoelastic materials exhibit rubber like behavior explained by the thermodynamic theory of polymer elasticity. A viscoelastic material has the following properties: hysteresis is seen in the stress-strain curve, and stress relaxation occurs: step constant strain causes decreasing stress.

The modular liner subcomponent is a compressible liner designed to allow the shell subcomponent to comfortably accommodate the user's head anatomy.

The modular facemask subcomponent is a semi-rigid, breathable, barrier that assembles flush to the shell subcomponent to prevent facial fractures and opponent interference while maximizing visibility. The facemask couples to the shell subcomponent via taper locking posts and hook-and-loop fastener attachments that allow for easy removal and prevent iatrogenic injuries, obviating torsional face mask injuries, with an internal safety truss bar encircling the helmet like a halo for protection from craniomaxillofacial injuries.

The modular cervical protector is a hook-and-loop fastened removable hinged component that couples to the shell subcomponent to mitigate spine injuries and can receive modular cooling packs and sensing diagnostic components, for example, accelerometers, etc.

Given the high costs of present football helmets the present invention incorporates a one size fits all option which also allows the helmet to self-adjust depending on swelling secondary to weight loss/gain/fluid retention to keep helmet adherence to cranium yet not constrictive to maximize comfort and minimize concussions. This may obviate the need for player position specific helmet types.

Furthermore, the present invention also addresses the torsional injuries secondary to the facemask bars by eliminating them and incorporating a single unit visor. This solves the torsional forces generated by players grabbing the face masks and wrenching opponents to the ground.

Visibility in the present invention is enhanced by incorporating the clear visor instead of the traditional facemask bars which interfere with players visual fields. This feature of the present invention will further enhance the prevention of craniomaxillofacial injuries.

Preferred embodiments of the present invention utilize velour hook-and-loop fastener closures instead of common snaps and buckles to further reduce potential injuries.

To compensate for the “closed” effect of the visor, its lower portion, covering the nose and lower face, is widely perforated for air circulation. Between these sections an extra single bar is placed within the visor itself connecting to the helmet in a “halo” fashion, encircling the head and increasing the strength and stability of the helmet further holding the head, face and neck in place during tackles, hits and pile-ons.

Hook-and-loop fasteners also facilitate rapid removal of the visor and replacement secondary to unanticipated breakage as well as rapid removal in cases of injury and to prevent iatrogenic injuries. There is no need to have special equipment, i.e. screw drivers, new screws available.

The external plastic surface of the helmet is smooth and continuous with the unitary and integral visor to reduce the risk of sudden deceleration reducing risk of cervical spine injury or concussion.

Because some studies have shown that there is still an increased possibility of neck injuries, the present invention includes a “break away” panel secured by hook-and-loop fasteners on the back of the helmet. Inserts on this panel are used for placement of cold packs for player comfort and help limit heat stroke. Also, on the field wireless sensors, accelerometers, EKG monitoring, EEG monitoring, and other apparatus can be placed here to field real-time information monitoring potential injuries.

In addition, the present invention incorporates the lighter, more resilient and energy absorbing material, such as polycarbonate, ABS plastic, or other plastics, Kevlar, carbon fiber composite, metal, or any combination thereof (such as carbon fiber reinforced polymer), for the shells without sacrificing strength and stability of the helmet.

The present invention also includes added ventilation over hair bearing areas but not usual impact points of frontal and parietal areas for more player comfort.

In an alternative embodiment, the porous core of the helmet has omnidirectionally interwoven honeycomb structures.

In another alternative embodiment, the porous core of the helmet has an omnidirectionally interwoven elliptical leafspring structure.

In a further embodiment, the porous core of the helmet has an omnidirectionally interwoven multi-start helical coil structure.

In another embodiment, the porous core of the helmet has a concave tetrahedral lattice.

In further embodiments, the porous core of the helmet has a deltahedral or polyhedral geometry.

The present invention contributes to a significant reduction in headform acceleration, minimizing the energy involved in impacts and collisions and/or the forces applied below those causing concussions.

Although the shock reducing helmet is described herein in terms of a preferred embodiment of a football helmet, it will be apparent to one of skill in the art that the shock reducing helmet may be adapted for use in other activities, both recreational and labor-related, that would benefit from increased protection from both linear and rotational impacts.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features of this invention, as well as the invention itself, both as to its structure and its operation, will be best understood from the accompanying drawings, taken in conjunction with the accompanying description, in which similar reference characters refer to similar parts, and in which:

FIG. 1 is a top perspective view of a shock reducing sports helmet of the present invention, showing the helmet body formed with ear openings and a full face shield flush with the helmet body;

FIG. 2 is an exploded view of a shock reducing sports helmet of the present invention, with the face shield removed;

FIG. 3 is a left side view of a shock reducing sports helmet of the present invention, as described in FIG. 1;

FIG. 4 is a front view of a shock reducing sports helmet of the present invention, as described in FIGS. 1 and 2;

FIG. 5 is a rear view of a shock reducing sports helmet of the present invention, showing the rear region of the outer shell of the helmet with a removable flap;

FIG. 6 is a lateral cross-sectional view of a shock reducing sports helmet of the present invention, as taken along line 6-6 of FIG. 3, showing the outer shell, the inner shell, an array of springs extending between the outer shell and the inner shell, and an exemplary skeleton as positioned within the shock reducing sports helmet during use;

FIG. 7 is a midsaggital cross-sectional view of a shock reducing sports helmet of the present invention, as taken along line 7-7 of FIG. 4, shows the interior of the inner shell as described in FIG. 6;

FIG. 8 is a transverse cross sectional view of a shock reducing sports helmet of the present invention, as taken along line 8-8 of FIG. 5, showing the inner shell from a top perspective;

FIG. 9 is an internal view of the inner shell of a shock reducing sports helmet of the present invention, showing the spring assembly;

FIG. 10 is a front view of a shock reducing sports helmet of the present invention, showing an alternative embodiment to the helmet described in FIG. 4 having a bar incorporated within the face shield that will circle the entire helmet;

FIG. 11 is a medial cross-sectional view of a shock reducing sports helmet of the present invention, showing an alternative embodiment of FIG. 7 having perforated chambers between the springs;

FIG. 12 is a medial cross-sectional view of a shock reducing sports helmet of the present invention, showing an enlarged view of FIG. 11;

FIG. 13 is a medial cross-sectional view of a shock reducing sports helmet of the present invention, showing a further enlarged view of FIG. 11;

FIG. 14 is a perspective cutaway view of an alternative preferred embodiment of a shock reducing helmet, showing the rigid shell and a chamber filled with honeycomb-shaped shock-absorbing structures;

FIG. 15 is a side cutaway view of the embodiment of FIG. 14;

FIG. 16 is a perspective cutaway view of an alternative preferred embodiment of a shock reducing helmet, showing the rigid shell and a chamber filled with hexagonal shock-absorbing structures;

FIG. 17 is a side cutaway view of the embodiment of FIG. 16;

FIG. 18 is a perspective cutaway view of an alternative preferred embodiment of a shock reducing helmet, showing the rigid shell and a chamber filled with hexagonal shock-absorbing structures;

FIG. 19 is a side cutaway view of the embodiment of FIG. 18;

FIG. 20 is a perspective cutaway view of an alternative preferred embodiment of a shock reducing helmet, showing the rigid shell and a chamber filled with leafspring shock-absorbing structures;

FIG. 21 is a side cutaway view of the embodiment of FIG. 20;

FIG. 22 is a perspective cutaway view of an alternative preferred embodiment of a shock reducing helmet, showing the rigid shell and a chamber filled with multi-start helical shock-absorbing structures;

FIG. 23 is a side cutaway view of the embodiment of FIG. 22;

FIG. 24 is a perspective cutaway view of an alternative preferred embodiment of a shock reducing helmet, showing the rigid shell and a chamber filled with a concave tetrahedral shock-absorbing structures;

FIG. 25 is a side cutaway view of the helmet of FIG. 24; and

FIG. 26 is a perspective view of a preferred embodiment of a shock reducing helmet;

FIG. 27 is a side view of the embodiment of FIG. 26; and

FIG. 28 is a side cutaway view of the embodiment of FIG. 26.

DETAILED DESCRIPTION

Referring initially to FIG. 1, the Shock Reducing Sports Helmet of the present invention is shown and generally designated 10. Helmet 10 includes a body 12 formed with a left ear opening 26, right ear opening 46 (shown in FIG. 2), and a full face shield 14 flush with the helmet body 12.

The helmet body 12 has a crown region 20, front region 18, rear region 22, left side region 24, and right side region 54 (shown in FIG. 4). The helmet body 12 is made of an outer shell 16 and an inner shell 38.

The face shield 14 is preferably made of a clear transparent polycarbonate, such as Lexan, and attaches flush with the outer shell 16 of the helmet body 12 to eliminate visibility interference and rotational injuries caused by knocking or pulling the metal bars of face shields used in prior art.

The face shield 14 attaches to the helmet body 12 by hinges 42 (shown in FIG. 2) on the right side of the face shield 32 and fasteners 36 on the left side of the face shield 34. Alternatively, the location of the hinges 42 and fasteners 36 may reverse sides. The front of the face shield 30 has vents 28 to allow for ventilation and verbal communication.

Referring now to FIG. 2, an exploded view of the Shock Reducing Sports Helmet of the present invention, with the face shield 14 removed. This exploded perspective shows the helmet 10 as described in FIG. 1 with additional features, including a view of the interior of the helmet 47, the relative thickness between the outer shell and inner shell 48, and the inner wall 19 and outer wall 17 of the outer shell 16. The outer shell 16 is preferably made of the strongest and lightest weight materials, such as polycarbonate, ABS plastic, or other plastics, Kevlar, carbon fiber composite, metal, or any combination thereof (such as carbon fiber reinforced polymer), to provide a high strength to weight ratio and to minimize fracture. Alternatively, a metal alloy may be used for the outer shell.

FIG. 2 also shows the right ear opening 46, of the helmet body 12. The ear openings 26 and 46 are situated on the helmet body 12 to be generally in line with the ears of the user of the helmet to allow for transmission of sound.

Additionally, FIG. 2 shows the hinges 42 mentioned above that attach the face shield 14 to the helmet body 12 via hinge attachment points 44 on the right side region 54 (shown in FIG. 4) of the helmet body 12. The fasteners 36 on the left side of the face shield 34 connect to the left side region 22 of the helmet body 12 via fastener connection points 40. As previously mentioned, the location of the hinges 42 and fasteners 36 and their associated connection points may reverse sides.

Finally, FIG. 2 shows a chin strap 50 with chin strap fasteners 52 that attach to one or more chin strap connection points (not shown on figures) on the helmet body 12. The chin strap 50 fits snugly around the chin of user and connects to both sides of the helmet body 12 to prevent the helmet 10 from falling off user's head.

Referring now to FIG. 3, a left side view of the Shock Reducing Sports Helmet of the present invention, showing helmet 10 as described in FIG. 1.

Referring now to FIG. 4, a front side view of the Shock Reducing Sports Helmet of the present invention, showing helmet 10 as described in FIGS. 1 and 2, and additionally showing the right side region 54 of the helmet body 12.

As seen in FIG. 4, vents 28 are orifices in the face shield 14 that allow for airflow in and out of the helmet 10. In a preferred embodiment, vents 28 are hexagon-shaped in order to allow for an optimal balance between airflow and strength. However, the appropriate balance may vary between different types of activity and from individual to individual. Some embodiments use slots instead of hexagons for vents 28 in order to increase airflow. Other embodiments include helmets 10 with triangle-shaped vents 28, helmets 10 with circular vents 28, helmets 10 with other shapes of vents 28, and helmets 10 with mixed shapes of vents 28.

Referring now to FIG. 5, a rear view of the Shock Reducing Sports Helmet of the present invention, showing helmet 10 as described in FIG. 4, and additionally showing a modular cervical protector 55, which is connected to the helmet body 12 by hook-and-loop fasteners so it may be easily opened in the event of a neck injury to insert cooling pads or accelerometers. Other monitoring devices such as, for example, EEG electrodes, may also be inserted through the opening. In one embodiment, the hook-and-loop fasteners of modular cervical protector 55 hold the modular cervical protector 55 closed, and may be disengaged in order to open modular cervical protector 55 like a flap. In another embodiment, the hook-and-loop fasteners are disengaged in order to remove the modular cervical protector 55 entirely.

Referring now to FIG. 6, a lateral cross-sectional view of the Shock Reducing Sports Helmet of the present invention, as taken along line 6-6 of FIG. 3, showing the outer shell 16, the inner shell 38, an array of springs 56 extending between the outer shell 16 and the inner shell 38, and an exemplary skeleton 66 as positioned within the Shock Reducing Sports Helmet during use.

The inner shell 38 includes springs 56, spring gaps 62 (as shown in FIG. 9), chambers 58, and side chambers 60, which are distributed in a manner to maximize shock absorption upon linear and rotational impact. Springs 56 are coil springs in some preferred embodiments, and cylindrical wave springs in other preferred embodiments. Other springs or spring-like elements exhibiting appropriate compression characteristics may be used for springs 56. Chambers 58 between the springs 56 and side chambers 60 may be filled with a viscous polymer or gas to dampen recoil of the springs 56 and vary in density as a function of placement along the skull 64. Chambers 58 between the springs 56 and chambers 60 also have, in some embodiments, an inner core that is porous, trabecular, or honeycomb, or any combination thereof, in geometric structure. Some embodiments of the trabecular structure are symmetrical, and other embodiments are asymmetrical and irregular. Both symmetrical and asymmetrical trabeculae are used in some embodiments of the shock reducing helmet.

In an alternative embodiment, chambers 58 between the springs 56 are empty, and perforations in the outer shell 16 allow gas exchange to dampen the spring load upon impact force, while chambers 60 are filled with a porous honeycomb or trabecular structure.

Referring now to FIG. 7, a medial cross-sectional view of the Shock Reducing Sports Helmet of the present invention, as taken along line 7-7 of FIG. 4, showing the interior of the inner shell 38 as described in FIG. 6. A compressible foam liner lines inner shell 38 for fit in some embodiments; alternatively, a head sock may be used.

Referring now to FIG. 8, a lateral-cross sectional view of the Shock Reducing Sports Helmet of the present invention, as taken along line 8-8 of FIG. 5, showing the inner shell 38 as described in FIG. 6 from a top perspective.

Referring now to FIG. 9, an internal view of the inner shell 38 of the Shock Reducing Sports Helmet of the present invention, showing the spring assembly as described in FIG. 6, and additionally showing spring gaps 62 to demonstrate variable spacing of the springs 56 as a function of placement along the skull 64.

Referring now to FIG. 10, a front view of the Shock Reducing Sports Helmet of the present invention, showing an alternative embodiment to the helmet 10 described in FIG. 4 with a “bar,” or circumferential structural supporting rib 68 incorporated within the face shield that encircles the helmet body 12 to further reinforce stability of the helmet 10.

Referring now to FIG. 11, a medial cross-sectional view of the Shock Reducing Sports Helmet of the present invention, showing an alternative embodiment to the helmet 10 described in FIG. 7 with perforations 70 in the chambers between the springs that mimic trabeculae found in trabecular cancellous bone, also known as spongy bone to allow for gas exchange to dampen the spring load upon impact.

Referring now to FIG. 12, a medial cross-sectional view of the Shock Reducing Sports Helmet of the present invention, showing an enlarged view of FIG. 11. Chambers 58 are filled with a porous plastic or metal material that matches the outer shell 16 and inner shell 38 in material properties, but has a porous structure resulting in perforations 70.

Referring now to FIG. 13, a medial cross-sectional view of the Shock Reducing Sports Helmet of the present invention, showing a further enlarged view of FIG. 11. The perforations 70 are arranged in a pattern in some embodiments, and in other embodiments are arranged irregularly.

FIGS. 14-25 illustrate shock-absorbing structures used to absorb impact energy in various embodiments of the shock reducing helmet described herein. The shock-absorbing structures are placed in the core of the helmet, usually extending from the outer shell (e.g. outer shell 16) to the inner shell (e.g. inner shell 38), and filling at least a portion, but in some embodiments all, of the core of the helmet. The helmet thus has a trabecular core region composed of one or more of the below-described shock-absorbing structures. The shock-absorbing structures absorb impact energy by a resilient, elastic, viscoelastic, or frangible dynamic response to compression. Moreover, the shock-absorbing structures have a nonuniform density, anisotropic configuration, or both in some embodiments.

In order to make some embodiments of a shock reducing helmet, 3D printing is used to create shock-absorbing structures that were previously not available with manufacturing processes such as casting or extrusion.

Some preferred embodiments of the shock-absorbing structures are made from a shape-memory alloy, which allows portions of the helmet to be deformed during impact and later returned to their original shape. Some embodiments use superelastic alloys, such as a nickel titanium shape-memory alloy, allowing the helmet to recover its original shape on its own after impact, without the need for a temperature change.

Referring now to FIG. 14, a perspective cutaway view of an alternative preferred embodiment of a shock reducing helmet shows the rigid shell and a chamber 58 filled with a cage structure, or, more particularly, honeycomb-shaped shock-absorbing structures 120. Each structure 120 is a chain of hexagonal elements extending from the outer shell 16 to the inner shell 38. Each hexagonal element has a wall 122 and an aperture 124 extending from one end of the hexagonal element to the other. The walls 122 increase in thickness and the apertures 124 decrease in cross-sectional area along the length of the structure 120 as it extends toward the inner shell 38. As shown, the shock-absorbing structures 120 are placed in alternating orientations. Moreover, in some embodiments the shock absorbing structures 120 vary in density of their placement throughout the helmet, providing varying stiffness between regions of the helmet.

Structures 120 act as compression springs, absorbing the energy of impacts against the helmet. Due to the increasing thickness of walls 122, the structures 120 exhibit greater stiffness, or resistance to deflection nearer the inner shell 38.

In a preferred embodiment, shock-absorbing structures 120 are placed in regions of the helmet that do not have springs 56. In another embodiment, shock absorbing structures 120 are used throughout the helmet instead of springs 56.

Referring now to FIG. 15, a side cutaway view of the alternative preferred embodiment of FIG. 14 is illustrated. As seen, the shock-absorbing structures 120 alternate in orientation, both from left to right and front to back.

Referring now to FIG. 16, a perspective cutaway view of an alternative preferred embodiment of a shock reducing helmet shows the rigid shell and a chamber 58 filled with a cage structure or, more particularly, hexagonal shock-absorbing structures 130. Most of the top and bottom side of each hexagon are provided by the outer shell 16 and the inner shell 38 of the helmet. Shock-absorbing structures 130 may be made from a nickel-titanium shape-memory alloy, polycarbonate, ABS plastic, or other plastics, Kevlar, carbon fiber composite, metal, or any combination thereof (such as carbon fiber reinforced polymer), which allows portions of the helmet to be deformed during impact and later returned to their original shape.

Referring now to FIG. 17, a cutaway side view of the alternative preferred embodiment of FIG. 16 is shown. As seen, the shock-absorbing structures 130 alternate in orientation, both from left to right and front to back. In a preferred embodiment, shock-absorbing structures 130 are placed in regions of the helmet that do not have springs 56. In another embodiment, shock absorbing structures 130 are used throughout the helmet instead of springs 56.

Referring now to FIG. 18, a perspective cutaway view of an alternative preferred embodiment of a shock reducing helmet shows the rigid shell and a chamber 58 filled with hexagonal shock-absorbing structures 135. Most of the top and bottom side of each hexagon are provided by the outer shell 16 and the inner shell 38 of the helmet. Shock-absorbing structures 135 may be made from steel in a preferred embodiment, but may be made from other materials such as a nickel-titanium shape-memory alloy, polycarbonate, ABS plastic, or other plastics, Kevlar, carbon fiber composite, metal, or any combination thereof (such as carbon fiber reinforced polymer).

Referring now to FIG. 19, a cutaway side view of the alternative preferred embodiment of FIG. 18 is shown. As seen, the shock-absorbing structures 135 alternate in orientation, both from left to right and front to back. In a preferred embodiment, shock-absorbing structures 135 are placed in regions of the helmet that do not have springs 56. In another embodiment, shock absorbing structures 135 are used throughout the helmet instead of springs 56.

Referring now to FIG. 20, a perspective cutaway view of an alternative preferred embodiment of a shock reducing helmet shows the rigid shell and a chamber 58 filled with beam structures. More particularly, chamber 58 is filled with leafspring shock-absorbing structures 140. Shock-absorbing structures 140 may be made from a nickel-titanium shape-memory alloy, polycarbonate, ABS plastic, or other plastics, Kevlar, carbon fiber composite, metal, or any combination thereof (such as carbon fiber reinforced polymer), which allows portions of the helmet to be deformed during impact and later returned to their original shape.

Referring now to FIG. 21, a cutaway side view of the alternative preferred embodiment of FIG. 20 is shown. As seen, the shock-absorbing structures 140 are placed in sets of two opposing leafspring structures, and the sets alternate in orientation, both from left to right and front to back. In a preferred embodiment, shock-absorbing structures 140 are placed in regions of the helmet that do not have springs 56. In another embodiment, shock absorbing structures 140 are used throughout the helmet instead of springs 56.

Referring now to FIG. 22, a perspective cutaway view of an alternative preferred embodiment of a shock reducing helmet shows the rigid shell and a chamber 58 filled with helical shock-absorbing structures 150. Shock-absorbing structures 150 may be made from a nickel-titanium shape-memory alloy, from a nickel-titanium shape-memory alloy, polycarbonate, ABS plastic, or other plastics, Kevlar, carbon fiber composite, metal, or any combination thereof (such as carbon fiber reinforced polymer), which allows portions of the helmet to be deformed during impact and later returned to their original shape. Each shock-absorbing structure 150 has between one and five congruent intertwined nickel-titanium shape-memory alloy, polycarbonate, ABS plastic, or other plastics, Kevlar, carbon fiber composite, metal, or any combination thereof (such as carbon fiber reinforced polymer) material helices or resilient members. In one embodiment, shock-absorbing structures 150 may be wire structures, much like helical springs. In a preferred embodiment, structure 150 is a triple helix.

Referring now to FIG. 23, a cutaway side view of the alternative preferred embodiment of FIG. 23 is shown. In a preferred embodiment, shock-absorbing structures 150 are placed in regions of the helmet that do not have springs 56. In another embodiment, shock absorbing structures 150 are used throughout the helmet instead of springs 56.

Referring now to FIG. 24, a perspective cutaway view of an alternative preferred embodiment of a shock reducing helmet shows the rigid shell and a chamber 58 filled with a truss structure. More particularly, chamber 58 is illustrated as being filled with a lattice of tetrahedron shock-absorbing structures 160. As illustrated, in some embodiments the tetrahedral shape of the shock-absorbing structures 160 may have concave rather than straight edges. In a preferred embodiment, the lattice is made up of two layers of tetrahedron-shaped elements between the outer shell 16 and the inner shell 38 of the helmet. Shock-absorbing structures 160 are made from a nickel-titanium shape-memory alloy, polycarbonate, ABS plastic, or other plastics, Kevlar, carbon fiber composite, metal, or any combination thereof (such as carbon fiber reinforced polymer), which allows portions of the helmet to be deformed during impact and later returned to their original shape.

Referring now to FIG. 25, a cutaway side view of the alternative preferred embodiment of FIG. 24 is shown. As seen, the lattice of shock-absorbing structures 160 is made up of two layers of tetrahedron-shaped elements. In a preferred embodiment, shock-absorbing structures 160 are placed in regions of the helmet that do not have springs 56. In another embodiment, shock absorbing structures 160 are used throughout the helmet instead of springs 56.

Referring now to FIG. 26, a shock reducing helmet 200 is illustrated. Shock reducing helmet 200 is substantially similar to helmet 10 in materials, structure, and use, with the primary exceptions of the face mask 14 and the flap 55, which differences are discussed below. In all other respects, it is fully contemplated that for each component, the materials and structure of the corresponding structure of other embodiments described herein may also be used with helmet 200.

The helmet body 212 of helmet 200 covers the lower portion of a wearer's face, including the maxilla and mandible, thus requiring only a visor 214 smaller than the face shield 14 of helmet 10. In a preferred embodiment, visor 214 is made of a scratch-resistant, transparent polycarbonate. The body 212 of helmet 200 is made with an outer shell 216 and an inner shell 238 (shown in FIG. 28), creating a chamber 258. The body 212 has a left ear opening 226 and a right ear opening.

In an alternative embodiment, helmet 200 has a facemask 14 (shown in FIGS. 1-4) of which visor 214 forms a part.

Instead of modular cervical protector 55, helmet 200 has a removable cervical protector 255 attached to the rear portion of the base of helmet body 212. Removable cervical protector 255 may be easily removed in the event of a neck injury to insert cooling pads or an instrumentation pack that acquires, stores, and transmits data, such as an instrumentation pack containing accelerometers and other diagnostic instrumentation.

A circumferential structural supporting rib or halo 268, analogous to rib 68 shown in FIG. 10, is present in some preferred embodiments, and, for aesthetic purposes, integrated into the helmet shell rather than visibly present outside the helmet 200. In some embodiments, multiple halos 268 are present.

Referring now to FIG. 27, a side view of helmet 200 is illustrated, showing the position of visor 214 and removable cervical protector 255. As shown, visor 214 sits flush with the body 212 of helmet 200, making it difficult for another player to grab, thus avoiding torsional injuries generated by players grabbing the face masks and wrenching opponents to the ground.

Some embodiments of the removable cervical protector 255 extend up to the bottom of the halo 268, as illustrated by broken line 255A. Moreover, some preferred embodiments of the cervical protector 255, intended for use in environments where blows to the back of the head and neck are likely, have the same internal shock absorbing structures as the body 212 of helmet 200.

Referring now to FIG. 28, the chambers 258 between the outer shell 216 and the inner shell 238 are filled with one or more of the shock absorbing structures described in conjunction with FIGS. 14 through 25. In a preferred embodiment, the shock absorbing structures are used throughout the chambers 258 instead of the springs 56 used in several preferred embodiments of helmet 10, resulting in a modular core region at least partially, and in some embodiments completely, composed of the shock absorbing structures. In some embodiments, the shock absorbing structures are placed throughout the helmet 200 with a nonuniform density, while in other embodiments a uniform density is used.

The shock absorbing structures form a trabecular core region, and vary between embodiments in interlaced, independently aligned, patterned, and pseudo-randomly oriented. The shock absorbing structures absorb impact energy by a resilient, elastic, viscoelastic, or frangible dynamic response to compression.

Helmet 200 includes, in some embodiments, modular fasteners 274 for ancillary device compatibility. Fasteners 274 vary in number and position among embodiments, and may be found on the outside of helmet 200, on the inside of helmet 200, or both on the outside and on the inside of helmet 200. Fasteners 274 may be screws, bolts, flaps, cables, epoxy, straps, or any combination thereof. It is fully contemplated that the other embodiments of the shock reducing helmet described herein may also be equipped with fasteners such as fasteners 274.

As with helmet 10, a compressible foam liner lines inner shell 238 of helmet 200 for fit in some embodiments; alternatively, a head sock may be used.

While there have been shown what are presently considered to be preferred embodiments of the present invention, it will be apparent to those skilled in the art that various changes and modifications can be made herein without departing from the scope and spirit of the invention.

Claims

1. A helmet, comprising:

a helmet body, comprising a core surrounded by a shell; and

a cervical protector,

wherein the core comprises an internal shock absorbing structure that is less rigid than the shell, and

wherein the cervical protector is configured to allow the insertion of one or more of cooling packs and diagnostic devices.

2. The helmet as recited in claim 1, further comprising a transparent face mask comprising at least one vent.

3. The helmet as recited in claim 2, wherein the at least one vent comprises hexagonal vents.

4. The helmet as recited in claim 1, further comprising a visor sized and positioned to protect a wearer's eyes.

5. The helmet as recited in claim 4, wherein the visor is transparent.

6. The helmet as recited in claim 5, wherein the visor is made of a scratch-resistant transparent polycarbonate.

7. The helmet as recited in claim 1, wherein the cervical protector is removable to allow the insertion of one or more of cooling packs and diagnostic devices.

8. The helmet as recited in claim 1, wherein the cervical protector is openable to allow the insertion of one or more of cooling packs and diagnostic devices.

9. The helmet as recited in claim 1, wherein the core comprises variably placed compression springs selected from the group consisting of coil springs, helical springs, and wave springs.

10. The helmet as recited in claim 9, wherein the shell comprises at least one perforation configured to allow gas exchange to dampen the spring load upon impact force.

11. The helmet as recited in claim 9, wherein the core further comprises structures that mimic trabeculae found in trabecular cancellous bone also known as spongy bone.

12. The helmet as recited in claim 9, wherein the core further comprises at least one shock absorbing structure selected from the group consisting of honeycomb structures, hexagonal structures, leafspring structures, helical structures, tetrahedral structures, beam structures, wire structures, web structures, trabecular structures, cage structures, truss structures, and concave tetrahedral structures.

13. The helmet as recited in claim 1, wherein the core comprises at least one shock absorbing structure selected from the group consisting of honeycomb structures, hexagonal structures, leafspring structures, helical structures, tetrahedral structures, beam structures, wire structures, web structures, trabecular structures, cage structures, truss structures, and concave tetrahedral structures.

14. The helmet as recited in claim 13, wherein the at least one shock absorbing structure comprises a shape-memory alloy.

15. The helmet as recited in claim 14, wherein the shape-memory alloy exhibits superelasticity.

16. The helmet as recited in claim 15, wherein the shape-memory allow is nickel titanium alloy.

17. A helmet, comprising:

a body configured to cover the head and face of a wearer and having an aperture configured to be located around the eyes of the wearer when the helmet is worn, the body comprising a shell around a core comprising an internal shock absorbing structure that is less rigid than the shell;

a visor covering the aperture of the body; and

a removable cervical protective cover attached to a base of the body and configured to protect the wearer's neck,

wherein the internal shock absorbing structure comprises at least one shock absorbing structure selected from the group consisting of honeycomb structures, hexagonal structures, leafspring structures, helical structures, tetrahedral structures, beam structures, wire structures, web structures, trabecular structures, cage structures, truss structures, and concave tetrahedral structures.

18. The helmet as recited in claim 17, wherein the visor comprises a transparent material.

19. The helmet as recited in claim 18, wherein the transparent material is polycarbonate.

20. The helmet as recited in claim 17, wherein the visor comprises a polymer.

21. The helmet as recited in claim 20, wherein the polymer is Lexan.

22. The helmet as recited in claim 17, wherein the core comprises a shape-memory metal alloy.

23. The helmet as recited in claim 22, wherein the shape-memory alloy exhibits superelasticity.

24. The helmet as recited in claim 23, wherein the shape-memory allow is nickel titanium alloy.

25. The helmet as recited in claim 17, wherein the internal shock absorbing structure has a nonuniform density throughout the core.

26. The helmet as recited in claim 17, wherein the internal shock absorbing structure has an anisotropic configuration.

27. The helmet as recited in claim 17, wherein the shell comprises a material selected from the group consisting of metal, polycarbonate, ABS plastic, Kevlar, and carbon fiber.

28. The helmet as recited in claim 27, wherein the core comprises the same materials as the shell.

29. The helmet as recited in claim 27, wherein the core comprises different materials from the shell.

30. The helmet as recited in claim 17, wherein the removable cervical protective cover comprises an internal shock absorbing core.

31. The helmet as recited in claim 30, wherein the internal shock absorbing core of the removable cervical protective cover comprises at least one shock absorbing structure selected from the group consisting of honeycomb structures, hexagonal structures, leafspring structures, helical structures, tetrahedral structures, beam structures, wire structures, web structures, trabecular structures, cage structures, truss structures, and concave tetrahedral structures.