HELMET WITH IMPACT STRUCTURE

Abstract

Embodiments of helmets including impact structures are disclosed. An example helmet includes an exterior shell including an inner surface, an outer surface; and a lower perimeter edge adjoining the inner surface and the outer surface. The lower perimeter edge defines a recess positioned on each side of the exterior shell. The example helmet further includes an interior liner positioned along the inner surface of the exterior shell, and further includes an impact structure associated with each recess. The impact structure is positioned at least partially below the interior liner and the exterior shell, and the impact structure includes a contact interface positioned to abut the interior liner.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the filing benefit of U.S. Provisional Application No. 63/449,811, filed Mar. 3, 2023. This application is incorporated by reference herein in its entirety and for all purposes.

BACKGROUND

Mountain biking is an exciting and rewarding outdoor activity. However, injuries can occur when mountain biking. While helmets are essential protective equipment that should be worn to protect against head injuries and traumatic brain injuries, in some situations, the helmets themselves may cause injuries when a rider falls from a mountain bike. For example, a bottom edge of a full-face mountain bike helmet may impact and injure a shoulder or collar bone of the rider when the rider falls. Improvements to full-face mountain bike helmet designs that help avoid injury from mountain bike accidents is desirable.

BRIEF DESCRIPTION OF THE DRAWINGS

Non-limiting and non-exhaustive examples are described with reference to the following Figures. The elements of the drawings are not necessarily to scale relative to each other.

FIG. 1A is a diagram of a helmet according to an embodiment of the disclosure.

FIG. 1B is a diagram of the helmet of FIG. 1A without a helmet ring.

FIG. 1C is a diagram of the helmet ring according to an embodiment of the disclosure.

FIGS. 2A-2D are diagrams of portions of example impact structures according to various embodiments of the disclosure.

FIGS. 3A-3E are diagrams of portions of example impact structures according to various embodiments of the disclosure.

FIGS. 4A and 4B are diagrams of portions of an example impact structure according to various embodiments of the disclosure.

FIGS. 5A and 5B are diagrams of portions of an example impact structure according to various embodiments of the disclosure.

FIGS. 6A-6F are diagrams of portions of example impact structures according to various embodiments of the disclosure.

FIGS. 7A-7E are diagrams of portions of example impact structures according to various embodiments of the disclosure.

FIGS. 8A-8C are diagrams of portions of example impact structures according to various embodiments of the disclosure.

FIGS. 9A and 9B are diagrams of portions of an example impact structure according to various embodiments of the disclosure.

FIGS. 10A and 10B are diagrams of portions of an example impact structure according to various embodiments of the disclosure.

FIGS. 11A and 11B are diagrams of portions of an example impact structure according to various embodiments of the disclosure.

FIGS. 12A-12C are diagrams of portions of an example impact structure according to various embodiments of the disclosure.

DETAILED DESCRIPTION

One or more embodiments described herein include a helmet with an impact structure. In particular, an impact structure can be positioned around a lower portion of the helmet (e.g., to help cushion a bottom edge that may contact a user during falls or accidents). For example, the impact structure of the present disclosure can include a protective guard around the exterior shell edge defining a lower opening where a user's head is inserted into or withdrawn from the helmet. The protective guard can be positioned at certain segments of the exterior shell edge that can contact a user's collarbone, shoulder, sternum, etc. during accidents. In other examples, the impact structure of the present disclosure can include a protective guard around an entirety of the exterior shell edge at the lower opening.

In some examples, the impact structure can be positioned inside or adjacent to a recess defined by a lower perimeter edge of the exterior shell. Such a recess can provide additional room for placement of the impact structure, but without decreasing a clearance between the helmet and the user. In these or other examples, the impact structure can at least partially fill or cover the recess in a bottom-up fashion. That is, the impact structure can include one or more protective elements that are separate and distinct from an interior liner, such as an expanded polypropylene (EPP) layer positioned along an inner surface of the exterior shell. Thus, unlike some conventional helmets, the interior liner of the present disclosure does not extend downward from the helmet interior and into or adjacent to a recess. Rather, the impact structure of the present disclosure can extend up and into (or beside) the recess.

These and other embodiments are discussed below with reference to FIGS. 1-12C. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these Figures is for explanatory purposes only and should not be construed as limiting. Furthermore, as used herein, a system, a method, an article, a component, a feature, or a sub-feature including at least one of a first option, a second option, or a third option should be understood as referring to a system, a method, an article, a component, a feature, or a sub-feature that can include one of each listed option (e.g., only one of the first option, only one of the second option, or only one of the third option), multiple of a single listed option (e.g., two or more of the first option), two options simultaneously (e.g., one of the first option and one of the second option), or combination thereof (e.g., two of the first option and one of the second option).

FIGS. 1A-1B illustrate a helmet 100 in accordance with one or more embodiments of the present disclosure. As shown, the helmet 100 includes an exterior shell 101. The exterior shell 101 can include an outer surface 102 and an inner surface 103. In these or other examples, the exterior shell 101 can form a variety of sizes and shapes, including a full-head (or full-face) helmet configuration for sports such as downhill mountain biking, motocross racing, skiing, etc. For instance, FIGS. 1A-1B show such a helmet with the exterior shell 101 including a rounded dome portion in addition to chin bar (or chin guard) that wraps around a front half of the helmet 100. In other examples of the helmet 100, other structural variations can be included.

In one or more examples, the exterior shell 101 comprises a rigid material. The rigid material of the exterior shell 101 can be sufficiently resilient to impact forces. For example, the rigid material of the exterior shell 101 can be resistant to abrasion or deformation. Examples of a rigid material can include carbon fiber, a composite material, a metal material (e.g., a metal alloy), or combinations thereof. Relatedly, the exterior shell 101 can be formed in a variety of ways known to those of ordinary skill in the art (e.g., via thermo-molding processes).

Further shown, the helmet 100 can include an interior liner 104. The interior liner 104 can include a pad, strip, or insert (whether removable or nonremovable) of material positioned along the helmet interior. Additionally or alternatively, the interior liner 104 can include a soft shell, an insulation lining, an impact reduction layer, etc. Examples of the interior liner 104 include EPP, expanded polystyrene (EPS), another foam layer (e.g., open-cell foam, closed-cell foam, a nanocomposite smart foam), fabric layers, air padding, and the like.

In addition, the helmet 100 can include a helmet ring 105. The helmet ring 105 can include an impact structure 106. In some examples, the helmet ring 105 can further include a trim portion 108. In one or more examples, the helmet ring 105 includes the impact structure 106 on each side (e.g., opposing sides at left and right portions). In other examples, as will be discussed below in relation to subsequent figures, the impact structure 106 extends all the way around the helmet ring 105.

As used herein, the term “impact structure” can refer to an impact absorption element. For example, an impact structure can include a rigid material configured to plastically deform, break, shatter, crush, or collapse in response to a threshold impact force (e.g., an impact force typically experienced during a fall or accident). In certain cases, the threshold impact force is less than the amount of force required to break human bone (e.g., between 2000 newtons and 4000 newtons). As another example, an impact structure can include a pliant material configured to flex, bend, elastically deform, etc. In certain instances, an impact structure can include a combination of materials. For example, an impact structure can include a rigid material and a pliant material (e.g., a rigid body portion and a pliant insert positioned inside the rigid body portion). In specific implementations, an impact structure can include a polyvinyl chloride material, a thermoplastic polyurethane material, etc. additionally or alternatively, an impact structure can include a honeycomb or cellular insert, a liquid material, a gas material, EPP, EPS, another foam layer (e.g., open-cell foam, closed-cell foam, a nanocomposite smart foam), fabric layers, compliant mechanisms, etc.

The impact structure 106 can be positioned in a variety of locations along a lower perimeter edge 110. In FIG. 1B, the helmet ring 105 is omitted for purposes of illustration (e.g., to expose the lower perimeter edge 110). The lower perimeter edge 110 comprises the bottom helmet edge between the outer surface 102 and the inner surface 103 of the exterior shell 101. Thus, the lower perimeter edge 110 extends around a bottom opening into the helmet 100. In some examples, the lower perimeter edge 110 forms recesses 112. The recesses 112 can include pockets, slotted areas, or upward breaks in the exterior shell 101. Additionally or alternatively, the recesses 112 can include portions of the exterior shell 101 that are raised above a plane defined by (and substantially perpendicular to) at least a majority of the lower perimeter edge 110.

In these or other examples, each impact structure 106 is positionally associated with a recess 112 defined by the lower perimeter edge 110. Specifically, each impact structure 106 is positioned inside or adjacent to a corresponding recess 112. Additionally or alternatively (as will be described below), one or both impact structures 106 can extend beyond the recesses 112 to partially or entirely wrap around the lower perimeter edge 110. Further, those of ordinary skill in the art will appreciate that a recess 112 can be omitted in some examples. Thus, in certain alternative implementations, the helmet 100 can include impact structures without recesses.

Further aspects of an impact structure, such as the impact structure 106, are discussed further below in relation to subsequent figures. For instance, the following figures illustrate some example embodiments of an impact structure, including various features, positional configurations, modes of attachment to the helmet, etc.

In some examples, the helmet ring 105 includes a trim portion 108, as shown in FIG. 1C. As used herein, the term “trim portion” refers to a cover for the lower perimeter edge 110. In particular examples, a trim portion is devoid of one or more structural features (e.g., crush zones, core outs, support ridges, flexible inserts, etc.) provided by the impact structure 106. In some examples, the trim portion 108 includes a bumper or rounded element bonded to the lower perimeter edge 110 or other portion of the exterior shell 101 (e.g., to cover the lower perimeter edge 110). Additionally or alternatively, the trim portion 108 can include aesthetic regions that provide a colored or textured border for the helmet 100.

In some examples, the trim portion 108 is integrally connected to the impact structures 106 (as shown). In other examples, the trim portion 108 can include one or more discrete members configured to abut and/or adhere to the impact structures 106 along the lower perimeter edge 110. Additionally or alternatively, in some examples, the trim portion 108 can at least partially cover the impact structures 106 (e.g., like a shell or overmolding fitted over the impact structures 106).

In these or other examples, the trim portion 108 comprises a same or similar material as a portion of the impact structures 106 (e.g., polyvinylchloride or thermoplastic polyurethane). Additionally or alternatively, the trim portion 108 comprises a different material from the impact structures 106. For example, the trim portion 108 can include a fabric material, a silicone material, etc.

Any of the features, components, and/or parts, including the arrangements and configurations thereof shown in FIGS. 1A-1C can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and/or parts, including the arrangements and configurations thereof shown and described with reference to the other figures can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown in FIGS. 1A-1C.

The following sections describe various embodiments of an impact structure implemented within or adjacent to a helmet recess. In accordance with one or more such embodiments. FIGS. 2A-2D illustrate example impact structures that comprise thru-slots. The elements shown and described in relation to FIGS. 2A-2D can include the same or similar elements described above in relation to FIGS. 1A-1C.

In FIGS. 2A and 2D (respectively showing exterior and interior views) specifically, an impact structure 200 is positioned within a recess 201 defined by an exterior shell 202. The impact structure 200 is further positioned below an interior liner 218, as shown in FIG. 2D. The impact structure 200 includes thru-slots 206. The thru-slots 206, as depicted, including triangular holes that extend entirely through the impact structure 200 from an inner side to an outer side of the impact structure 200. In particular, the thru-slots 206 include alternating triangles with a sequence of triangles that point up and down in an alternating fashion. Further shown in FIG. 2A, a trim portion 208 extends outside the recess 201 (e.g., towards front and back portions of a helmet not expressly shown).

FIG. 2B shows a portion of an impact structure 210. The impact structure 210 comprises thru-slots 212. The thru-slots 212 include hexagonal-shaped holes that extend laterally through an entirety of the impact structure 210.

Similarly, FIG. 2C shows a portion of an impact structure 214 comprising thru-slots 216. The thru-slots 216 comprise circular holes that also extend laterally through an entirety of the impact structure 214.

As evident from FIGS. 2A-2D, impact structures can include a variety of different shaped thru-slots. The different geometrical configurations of the thru-slots can provide a desired material property, such as rigidity, impact energy absorption, etc. Additionally or alternatively, various manufacturing (e.g., molding) techniques can be employed to provide these or other thru-slots of an impact structure of the present disclosure.

Any of the features, components, and/or parts, including the arrangements and configurations thereof shown in FIGS. 2A-2D can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and/or parts, including the arrangements and configurations thereof shown and described with reference to the other figures can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown in FIGS. 2A-2D.

FIGS. 3A-3E illustrate an impact structure 300 positioned within the recess 201 in accordance with one or more examples of the present disclosure. The elements shown and described in relation to FIGS. 3A-3E can include the same or similar elements described above in relation to FIGS. 1A-1C. For example, as depicted in the external view of FIG. 3A, the impact structure 300 comprises a solid outside surface 302. Then, as shown in the cross-sectional view of FIG. 3B and the interior of view of FIG. 3C, the impact structure 300 comprises an inside surface 306 defining core-outs 304. The core-outs 304 extend partially, but not entirely, through the impact structure 300. The core-outs 304 can include a variety of different shapes, spatial configurations, depths, etc. (e.g., to impart one or more desired material properties and/or aesthetic properties). As depicted, the core-outs 304 include a combination of hexagonal and trapezoidal shapes, similar to a honeycomb configuration.

Additionally, as shown in FIG. 3B, impact structure 300 can be positioned adjacent to the interior liner 218 and the exterior shell 202. In specific embodiments, the impact structure 300 includes a contact interface 308 configured to abut the interior liner 218. In at least one example, the contact interface 308 is devoid of any attachment (e.g., bond, fastener, etc.) to the interior liner 218. Further, the impact structure 300 can include an attachment interface 310 configured to attach to the exterior shell 202. Thus, in some examples, the impact structure 300 is attached to the helmet only via the attachment interface 310, which can bond or fasten to the exterior shell 202.

It will be appreciated that the impact structure 300 can include myriad different cross-sections and attachment configurations than illustrated in FIG. 3B. For example, as shown in FIG. 3D, the attachment interface 310 is omitted in the impact structure 300. In such an example, the impact structure 300 is not attached to the exterior shell 202. Instead, the impact structure 300 positioned within the recess 201 can include a floating impact structure that is configured to abut the interior liner 218 and/or the exterior shell 202. Still, in other cases, the impact structure 300 is configured to be spaced apart from one or both of the interior liner 218 and/or the exterior shell 202 (e.g., by a predetermined gap, such as 1 mm to about 10 mm).

In these or other examples, as shown in FIG. 3E, the trim portion 208 adjacent to (and integrally connected with) the impact structure 300 can be attached to the exterior shell 202. For example, the trim portion 208 on one or both sides of the impact structure 300 can be attached to the exterior shell 202. In this manner, the trim portion 208 can positionally maintain the impact structure 300 within the recess 201, notwithstanding the impact structure 300 being a floating impact structure in some implementations.

Any of the features, components, and/or parts, including the arrangements and configurations thereof shown in FIGS. 3A-3E can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and/or parts, including the arrangements and configurations thereof shown and described with reference to the other figures can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown in FIGS. 3A-3E.

FIGS. 4A-4B respectively illustrate external-facing and internal-facing views of an impact structure 400 positioned within the recess 201 in accordance with one or more examples of the present disclosure. The elements shown and described in relation to FIGS. 4A-4B can include the same or similar elements described above in relation to FIGS. 1A-1C.

As shown, impact structure 400 can include ridges 402 interspaced by valleys 404. The height of the ridges 402 and the distance between each of the ridges 402 can be modified as may be desired (e.g., to achieve one or more material properties). For example, the ridges 402 can, in response to an impact force, collapse or shear from the impact structure 400 (thereby absorbing impact energy). As another example, the ridges 402 can, in response to an impact force, flex or bend in the direction of impact to impact structure 400. It will be appreciated that shaped or profile of the ridges 402 can comprise myriad different shapes or profiles. However, as shown, the impact structure 400 generally comprises a circular profile and therefore rounded or semi-circular ridges.

Any of the features, components, and/or parts, including the arrangements and configurations thereof shown in FIGS. 4A-4B can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and/or parts, including the arrangements and configurations thereof shown and described with reference to the other figures can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown in FIGS. 4A-4B.

The foregoing sections have discussed various impact structures and associated configurations with respect to a certain recess. However, the present disclosure is not so limited. Indeed, aspects of the present disclosure include impact structures that extend along a portion of a lower perimeter edge beyond a helmet recess, or even extend entirely around a lower perimeter edge. In accordance with one or more such embodiments, FIG. 5A illustrates an impact structure 500 extending around an entirety of a lower perimeter edge. FIG. 5B illustrates an example cross-section of the impact structure 500. The elements shown and described in relation to FIGS. SA-5B can include the same or similar elements described above in relation to FIGS. 1A-1C.

In particular, the impact structure 500 is positioned within the recess 201 and beyond. For example, the impact structure 500 extends around an entirety of a lower perimeter edge 110 of the helmet 100. In these or other examples, the impact structure 500 comprises thru-slots 502 and support ribs 504. The thru-slots 502 are similar to the thru-slots of the foregoing figures, albeit a different size, shape, and arrangement. Indeed, the thru-slots 502 are rectangular shaped, parallelogram-shaped, triangular shaped, and trapezoidal shaped. However, in other embodiments, the thru-slots 502 can be differently shaped (e.g., cube-shaped, circular shaped, etc.).

In addition, the impact structure 500 comprises the support ribs 504 that span laterally across a body portion of impact structure 500. In one or more examples, the support ribs 504 can provide increased structural integrity. Additionally or alternatively, the support ribs 504 can provide predetermined points of failure where the impact structure 500 can collapse in response to an impact force.

Additionally shown, an interior liner 506 can be positioned or configured to accommodate the impact structure 500. For example, as shown in FIG. 5B, an inner surface of the interior liner 506 is indented to be flush with (e.g., planar to) an inner surface of the impact structure 500. In this manner, the transition between the interior liner 506 and a separate discrete component (i.e., the impact structure 500) at an inner surface 508 is substantially smooth and less likely to catch on a user when placing or removing the helmet 100.

Any of the features, components, and/or parts, including the arrangements and configurations thereof shown in FIGS. 5A-5B can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and/or parts, including the arrangements and configurations thereof shown and described with reference to the other figures can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown in FIGS. 5A-5B.

The following sections will discuss example impact structures comprising a channel positioned within a body portion of an impact structure. Such impact structures can include a variety of features and configurations. In accordance with one or more such embodiments, FIGS. 6A-6F illustrate examples of an impact structure 600. The elements shown and described in relation to FIGS. 5A-5B can include the same or similar elements described above in relation to FIGS. 1A-1C.

In accordance with one or more embodiments. FIGS. 6A-6B respectively illustrate external-facing and internal-facing cross-sectional views of an impact structure 600 positioned within the recess 201 as similarly described above. The elements shown and described in relation to FIGS. 6A-6F can include the same or similar elements described above in relation to FIGS. 1A-1C.

As shown further in FIGS. 6C-6F illustrating example cross-sections, the impact structure 600 can include support ribs 602 that span laterally within a channel 603 defined by a body portion 604. The support ribs 602 can include a pliant material or a rigid material, as may be desired. In at least some examples, the support ribs 602 performed of the same material as the body portion 602.

In FIG. 6C, the support ribs 602 extend to a top 606 of the recess 201 and then further extend above the top 606 laterally adjacent to an inner surface of the exterior shell 201. Likewise, an inner wall of the body portion 604 extends upward beyond the top 606 of the recess 201 and is flush with an inner surface of the interior liner 218. In particular, the interior liner 218 comprises an indentation such that the inner wall of the body portion 604 is flash with the interior liner 218.

By contrast, in FIG. 6D, the support ribs 602 extend to the top 606 of the recess 201 (and in some cases leaving a small gap), but not above the top 606. The inner wall of the body portion 604, however, does extend upward beyond the top 606 of the recess 201 and is flush with an inner surface of the interior liner 218.

In FIG. 6E, neither of the support ribs 602 or the inner wall of the body portion 604 extends upward past the top 606 of the recess 201. FIG. 6F shows a perspective cross-sectional view of FIG. 6C.

In each of the cross-sections 6C-6F discussed above, an attachment portion of the impact structure 600 includes an outer wall of the body portion 604 attached to the outer surface of the exterior shell 201. A contact interface configured to abut (but not attach to) the interior liner 218 in the foregoing examples can include at least one of a top surface of the support ribs 602 or an inner wall of the body portion 604.

Any of the features, components, and/or parts, including the arrangements and configurations thereof shown in FIGS. 6A-6F can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and/or parts, including the arrangements and configurations thereof shown and described with reference to the other figures can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown in FIGS. 6A-6F.

As mentioned above, impact structures with a channel can include a variety of features within the channel. In certain cases, these impact structures can include an insert. In accordance with one or more embodiments, FIGS. 7A-7B respectively illustrate external-facing and internal-facing views of an impact structure 700 positioned within the recess 201 as similarly described above. The elements shown and described in relation to FIGS. 7A-7E can include the same or similar elements described above in relation to FIGS. 1A-1C.

As shown in FIGS. 7A-7B, the impact structure 700 includes a body portion 702. The body portion 702 further defines cutouts that expose an insert 704 at least partially encompassed of the body portion 702. As shown in FIG. 7C, the body portion 702 defines a channel 703 in which the insert 704 can be positioned. In these or other examples, the insert 704 can be positioned into the channel 703 through open ends of the body portion 702. Alternatively, the insert 704 can be positioned into the channel 703 through an open top defined by the body portion 702.

In these or other examples, the insert 704 can include a variety of different materials. In some examples, the insert 704 includes material that differs from the body portion 702. For example, the body portion 702 can include a rigid material such as PVC or TPU. By contrast, the insert 704 can include a pliant material. For instance, the insert 704 can include a honeycomb or cellular insert, sealed air-cell insert, foam insert, gel insert, elastic insert, etc. In other instances, the insert 704 can also include a rigid material such as a crush structure formed of PVC or TPU. Further, in at least some examples, the insert 704 can include a structure for directional impact absorption. For instance, a honeycomb or cellular insert can be directionally arranged or oriented to absorb impact from a first direction but not a second direction.

FIGS. 7D-7E illustrate a couple examples of the insert 704. In particular, FIG. 7D illustrates a portion of an example TPU insert with core-outs (e.g., as a crush structure). In addition, FIG. 7E illustrates a portion of an example honeycomb insert. In at least some examples, the inserts 704 can include a contact interface (e.g., a top surface) configured to abut (but not necessarily attach to) the interior liner 218.

Any of the features, components, and/or parts, including the arrangements and configurations thereof shown in FIGS. 7A-7E can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and/or parts, including the arrangements and configurations thereof shown and described with reference to the other figures can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown in FIGS. FIGS. 7A-7E.

The foregoing embodiments described above include an impact structure positioned within a recess defined by a lower perimeter edge of the exterior shell. However, the present disclosure is not so limited. Indeed, helmet embodiments disclosed herein include helmets with impact structures that extend along a lower perimeter edge devoid of a recess. In accordance with one or more such examples, FIGS. 8A-8C illustrate an impact structure 801. The impact structure 801 can extend around an entirety of a lower perimeter edge of a helmet 800, as shown in FIG. 8A. The elements shown and described in relation to FIGS. 8A-8C can include the same or similar elements described above in relation to FIGS. 1A-1C. Differently, however, FIG. 8A shows the helmet 800 comprises no recess formed in the lower perimeter edge.

FIGS. 8B-8C illustrate some example cross-sections of the impact structure 801. For example, FIG. 8B illustrates a body portion 802 defining core-outs 804 (as similarly described above in relation to FIGS. 3A-3C). In addition, the impact structure 801 in FIG. 8B is positioned to abut a bottom surface of the interior liner 218. As another example, FIG. 5C illustrates an example of the impact structure 801 in which the body portion 802 wraps at least partially around a portion of the interior liner 218 extending below the exterior shell 202. It will be appreciated that the cross-sections of FIGS. 8B-8C can be implemented along an entirety of the lower perimeter edge of the helmet 800.

In alternative examples, however, the cross-sections of FIGS. 8B-8C can be implemented at discrete portions along the lower perimeter edge of the helmet 800. For example, the impact structure 801 with the core outs 804 may be positioned at lateral left and right sides of the helmet 800 (e.g., at areas 806), and trim portions (devoid of impact structures) can extend around the remaining segments of the lower perimeter edge of the helmet 800. As another example, the impact structure 801 can be implemented with large segments of a lower perimeter edge (e.g. the first portion corresponding to a back half of the helmet or a second portion corresponding to a front half of the helmet). In at least some examples, these large segments of the lower perimeter edge be raised relative to another portion of the lower perimeter edge. For instance, the back half of the helmet can include a raised lower perimeter edge associated with an impact structure, and the front half of the helmet can include a trim portion.

Any of the features, components, and/or parts, including the arrangements and configurations thereof shown in FIGS. 8A-8C can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and/or parts, including the arrangements and configurations thereof shown and described with reference to the other figures can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown in FIGS. SA-8C.

FIGS. 9A-9B illustrate an impact structure 900 in accordance with one or more examples of the present disclosure. The impact structure 900 can extend around an entirety of a lower perimeter edge of a helmet comprising no recess. The elements shown and described in relation to FIGS. 9A-9B can include the same or similar elements described above in relation to FIGS. 1A-1C.

As depicted, the impact structure comprises core outs 902. The core outs 902 extend partially through the impact structure 900 and are a triangular-shaped. It will be appreciated, however, that the impact structure 900 can include a variety of different features and/or structures. For example impact structure 900 can include any configuration of an impact structure described above, including core outs or thru-slots of myriad different shapes and sizes (which can lend to a desired level of impact absorption, rigidity, etc.).

Any of the features, components, and/or parts, including the arrangements and configurations thereof shown in FIGS. 9A-9B can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and/or parts, including the arrangements and configurations thereof shown and described with reference to the other figures can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown in FIGS. 9A-9B.

As mentioned above, impact structures of the present disclosure are not limited to being positionally associated with a helmet recess. The following sections discuss example impact structures that can be positioned along a lower perimeter edge within a helmet recess but also along a lower perimeter edge extending away from the helmet recess (e.g., towards a front or back half of the helmet). In accordance with one or more such examples, FIGS. 10A-10B illustrate an impact structure 1000. The elements shown and described in relation to FIGS. 10A-10B can include the same or similar elements described above in relation to FIGS. 1A-1C.

In FIG. 10A, the impact structure 1000 is positioned along the lower perimeter edge forming each recess 201. In addition, the impact structure 1000 extends forward (towards a front of the helmet) along the lower perimeter edge outside of the recess 201. In these or other examples, the impact structure 1000 forms a single, continuous impact structure extending around a front half of the helmet from each of the recesses 201. Further, a trim portion 1002 can extend around a back half of the helmet. In certain examples, longitudinal ends of the trim portion 1002 can abut (and in some cases, adhere to) respective ends of the impact structure 1000.

FIG. 10B shows an opposite configuration from FIG. 10A. In particular, the impact structure 1000 is positioned along the recesses 201 and extends backward (towards a back of the helmet) along the lower perimeter edge outside of the recess 201. In these or other examples, the impact structure 1000 forms a single, continuous impact structure extending around a back half of the helmet from each of the recesses 201. Further, the trim portion 1002 can extend around a front half of the helmet. In certain examples, longitudinal ends of the trim portion 1002 can abut (and in some cases, adhere to) respective ends of the impact structure 1000.

It will be appreciated that impact structure 1000 can include one or more structural configurations discussed above (e.g., core outs, thru-slots, inserts, etc.). Indeed, any of the features, components, and/or parts, including the arrangements and configurations thereof shown in FIGS. 10A-10B can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and/or parts, including the arrangements and configurations thereof shown and described with reference to the other figures can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown in FIGS. 10A-10B.

FIGS. 11A-11B illustrate an impact structure 1100 in accordance with one or more examples of the present disclosure. The impact structure 1100 can extend along a lower perimeter edge through a recess 201 and further extend towards a front or back half of the helmet, as described above in relation to FIGS. 10A-10B. The elements shown and described in relation to FIGS. 11A-11B can include the same or similar elements described above in relation to FIGS. 1A-IC.

In particular, the impact structure 1100 can include a solid outer surface plus with the outer surface of the exterior shell 202, as shown in FIG. 11A. On the interior side, impact structure 1100 can include core outs 1104. The core outs 1104 can be sized, shaped, and spatially arranged in myriad different ways (e.g., to provide the desired structural properties).

In addition, as discussed above, the trim portion 1102 can abut (and in some cases attach to) the impact structure 1100 (e.g., at a contact area 1106 adjacent to the recess 201). In at least some alternative examples, the impact structure 1100 is positionally limited to the recess 201. In such a case, an additional trim portion (not shown) can abut (and in some cases, adhere to) the impact structure 1100 at another contact area 1108 adjacent to the recess 201, opposite the contact area 1106. Such a helmet configuration can include a 4-piece arrangement of impact structures and trim portions. Specifically, two impact structures can be positioned along recesses 201, and two trim portions can be positioned along a lower perimeter edge outside of the recesses 201.

Any of the features, components, and/or parts, including the arrangements and configurations thereof shown in FIGS. 11A-11B can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and/or parts, including the arrangements and configurations thereof shown and described with reference to the other figures can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown in FIGS. 11A-11B.

The following section discusses another type of embodiment in which the interior liner 218 can extend downward from the helmet interior to be positioned proximate to a helmet recess. In so doing, the interior liner 218 can include an increased amount of surface area available for in-molding components. In accordance with one or more such examples, FIGS. 12A-12C illustrate an impact structure 1200. The elements shown and described in relation to FIGS. 12A-12C can include the same or similar elements described above in relation to FIGS. 1A-1C.

As shown, the impact structure 1200 can include thru-slots 1202 that extend laterally through the impact structure 1200. The thru-slots 1202 expose a lower portion of the interior liner 218 positioned adjacent to an inner surface of the impact structure 1200. The interior liner 218 abuts the impact structure 1200, but is not attached thereto. In this example configuration, the lower portion of the interior liner 218 is indented such that only the impact structure 1200 is positioned within the recess 201. That is, the lower portion of the interior liner 218 dog-legs inward away from the recess 201 defined by the lower perimeter edge of the exterior shell 202.

As shown in FIG. 12C, the downward extension of the interior liner 218 provides additional surface area for in-molded components 1204. Additional or alternative in-molded components are also herein contemplated.

Any of the features, components, and/or parts, including the arrangements and configurations thereof shown in FIGS. 12A-12C can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and/or parts, including the arrangements and configurations thereof shown and described with reference to the other figures can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown in FIGS. 12A-12C.

The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the embodiments to the precise forms disclosed. For instance, the terms “including” or “includes” as used in the specification shall have the same meaning as the term “comprising.”

Various embodiments and aspects of the invention(s) are described with reference to details discussed herein, and the accompanying drawings illustrate the various embodiments. The description above and drawings are illustrative of the invention and are not to be construed as limiting the invention. In particular, the drawings are not necessarily drawn to scale and may be depicted in a manner best suited for illustration purposes. Thus, the drawings may omit certain aspects (or may otherwise be modified) for illustration purposes to describe some example embodiments and implementations.

It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings. Indeed, various inventions have been described herein with reference to certain specific aspects and examples. However, they will be recognized by those skilled in the art that many variations are possible without departing from the scope and spirit of the inventions disclosed herein. The scope of the invention is, nonetheless, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims

1. A helmet comprising:

an exterior shell comprising: an inner surface; an outer surface; and a lower perimeter edge adjoining the inner surface and the outer surface, the lower perimeter edge defining a recess positioned on each side of the exterior shell;

an interior liner positioned along the inner surface of the exterior shell; and

an impact structure associated with each recess and positioned at least partially below the interior liner and the exterior shell, wherein the impact structure comprises a contact interface positioned to abut the interior liner.

2. The helmet of claim 1, wherein the impact structure defines a plurality of cutouts.

3. The helmet of claim 1, wherein the plurality of cutouts define a plurality of crushable features configured to plastically deform or break upon contact with an object at a threshold impact force.

4. The helmet of claim 1, wherein the impact structure defines a plurality of thru-slots.

5. The helmet of claim 1, wherein the impact structure comprises a body portion defining a channel extending longitudinally through the body portion.

6. The helmet of claim 5, wherein the impact structure comprises a plurality of support ribs positioned within the channel.

7. The helmet of claim 5, wherein:

the body portion comprises a first material; and

the impact structure comprises an insert positioned within the channel, the insert comprising a second material that differs from the first material.

8. The helmet of claim 7, wherein:

the first material comprises a rigid material; and

the second material comprises a pliant material.

9. The helmet of claim 1, wherein the impact structure associated with each recess is integrally connected to each other to form a single, contiguous impact structure by extending at least forward or backward along a portion of the lower perimeter edge beyond the recess positioned on each side of the exterior shell.

10. The helmet of claim 9, wherein the single, contiguous impact structure extends along an entirety of the lower perimeter edge.

11. The helmet of claim 9, further comprising a trim member extending at least partially along another portion of the lower perimeter edge, the trim member comprising first and second opposing ends that abut respective ends of the single, contiguous impact structure.

12. The helmet of claim 1, further comprising a set of trim members extending along a portion of the lower perimeter edge outside of the recess, each trim member of the set of trim members abutting the impact structure associated with each recess.

13. The helmet of claim 1, wherein the impact structure comprises one of polyvinyl chloride or thermoplastic polyurethane.

14. The helmet of claim 1, wherein the contact interface of the impact structure is devoid of attachment to the interior liner.

15. The helmet of claim 1, wherein the impact structure is attached to at least one of the lower perimeter edge or the outer surface of the exterior shell.

16. A helmet comprising:

an exterior shell comprising: an inner surface; an outer surface; and a lower perimeter edge adjoining the inner surface and the outer surface;

an interior liner positioned along the inner surface of the exterior shell; and

an impact structure extending along at least a first portion of the lower perimeter edge and positioned at least partially below the interior liner and the exterior shell, wherein the impact structure is positioned to abut the interior liner.

17. The helmet of claim 16, wherein the impact structure extends along an entirety of the lower perimeter edge.

18. The helmet of claim 16, further comprising a trim member extending along at least a second portion of the lower perimeter edge different from the first portion of the lower perimeter edge.

19. The helmet of claim 18, wherein:

the first portion of the lower perimeter edge corresponds to a back half of the helmet; and

the second portion of the lower perimeter edge corresponds to a front half of the helmet.

20. The helmet of claim 19, wherein the first portion of the lower perimeter edge is raised relative to the second portion of the lower perimeter edge.

21. The helmet of claim 16, wherein the impact structure is attached to at least one of the lower perimeter edge or the outer surface of the exterior shell.

22. An impact structure for attaching at least partially around a lower perimeter edge of a helmet, the impact structure comprising:

an attachment interface configured to attach to an exterior shell of a helmet and at least partially obscure a lower perimeter edge of the helmet;

a contact interface configured to abut an interior liner of the helmet; and

a body portion comprising a crushable region positionable at least along lateral sides of the lower perimeter edge of the helmet, the body portion being integrally connected to the attachment interface and the contact interface.

23. The impact structure of claim 22, wherein the crushable region is positionable within a recess defined by the lower perimeter edge of the helmet.