Note: Descriptions are shown in the official language in which they were submitted.
SYSTEM AND METHOD FOR CUSTOM FORMING A PROTECTIVE HELMET FOR A
CUSTOMER'S READ
RELATED APPLICATIONS
[0001]
TECHNICAL FIELD
[0002] This disclosure relates to a system and method for custom
forming a
protective helmet for a customer's head, such as a helmet for a cyclist,
football player, hockey
player, or motor sports participant. In particular, the system and method
include equipment and
methods for capturing and receiving captured data from customers or potential
customers and
arranging the data for three-dimensional analysis.
BACKGROUND
[0003] For helmet-wearing athletes in many sports, beyond the safety
aspects of the
protective helmet, additional considerations can include helmet fit and
airflow through the
helmet. Improvements in fit comfort and airflow can reduce distractions to the
athlete and
thereby improve performance.
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[0004] Conventional helmet creation technology has designed helmets
with the
assumption that human heads are similar and that head circumference is the
most important factor in
choosing an appropriate helmet. Adjustments to the standard helmet are then
made by adding
different thicknesses of padding between the customer's head and the inner
surface of the helmet.
These assumptions, however, have resulted in helmets that do not fit
correctly, tend to slip around on
the customer's head, rattle on the customer's head when vibration occurs in
the customer's body
during activities in the sport, or to create pressure points on the customer's
head and face to try to
keep the helmet in place even though the padding does not fit right or where
the customer's head is
too big to have padding between the head and the helmet protective material.
Systems that conform
to a customer's head developed by Giro and Bell in the 1990 's do a remarkable
job of stabilizing the
a helmet on a customer's head. However, previously developed fit systems do
not totally eliminate
reliance on the requirement for additional padding by the customer to adapt
the standard helmets to
the customer's head for a more comfortable fit.
[0005] While scanning systems for human body parts are known, they
suffer from a
number of significant limitations and deficiencies. For example, the scanning
equipment is
expensive, bulky and requires the scanner and the subject to be in the same
place at the same time.
This requirement limits the easy and cost effective access for the general
public as the scanner
equipment is very expensive, difficult to transport and must have trained
personnel to use it.
Additionally, some head shape scanning technologies are susceptible to false
readings due to
moisture on the head and hair bulk. Conventional helmet creating technologies
are not practical for
creating custom head shape helmets because they are expensive and the molds
are expensive. It is
desirable to form a custom fit helmet for customers without the need of
expensive scanning and
manufacturing equipment, and to create that custom fit helmet quickly and
without requiring separate
custom molds for each helmet.
SUMMARY
[0006] A need exists for a custom-fitted helmet and a method for
making the same.
Accordingly, in an aspect, a method of making a custom-fitted helmet can
comprise, at a first
location, obtaining head data for a customer's head comprising a length, a
width, and at least one
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head contour. Generating, with at least one processor, a computerized three
dimensional (3D)
headform matching the customer's head length, width, and head contour from the
head data.
Comparing the 3D headform to a helmet safety standard. At a second location
different from the
first location, forming a custom-fitted helmet based on the 3D headform
wherein the custom-
fitted helmet satisfies the safety standard and comprises an inner surface
comprising a
topography that conforms to the length, width, and at least one contour of the
customer's head.
[00071 The method of making the custom-fitted helmet can further
comprise
obtaining head data for the customer's head by obtaining images of a
deformable interface
member disposed on the customer's head, wherein a thickness of the deformable
interface
member approximates a thickness of a padding layer disposed within the custom-
fitted helmet.
Obtaining the images can be accomplished by using an optical sensor, a camera,
or a laser.
Obtaining images of the deformable interface member that can comprise
measurement points.
Obtaining images that can comprise a marker of a known size. Obtaining the
head data can
comprise gathering the head data using a non-contact sensor positioned
adjacent the customer's
head. Updating a customer's head data can occur after at least six months by
measuring at least
the customer's updated head length and updated head width. Obtaining the head
data at the first
location by capturing a photographic image of the customer's head can include
the first location
being a customer's home, and sending the captured photographic image of the
customer's head
from the customer's home to the at least one processor located a location
remote from the
customer's home. Obtaining the head data at the first location can be
accomplished by capturing
a photographic image of the customer's head, wherein the first location is a
store, and sending
the captured photographic image of the customer's head from the store to the
at least one
processor located a location remote from the store. The inner surface of the
custom-fitted helmet
can be formed comprising a surface topography that is proportional to the
length, width, and at
least one contour of the customer's head. A graphical computerized 3D headfonn
can be
generated from the head data, the helmet safety standard can be provided as a
graphical 3D
helmet safety standard, and the 3D headform can be compared to the helmet
safety standard by
positioning the graphical 3D headform within the graphical 3D helmet safety
standard to
determine a size and shape of the inner surface of the custom-fitted helmet.
The helmet safety
standard can be provided comprising a certified surface. The helmet safety
standard can be
provided comprising a test line. A helmet base unit can be selected comprising
a surface
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comprising a size and shape different than a size and shape of the inner
surface of the custom-
fitted helmet and the inner surface of the custom-fitted helmet can be formed
by removing
expanded polystyrene (EPS) from the helmet base unit using a computer
numerical control
(CNC) machine. The inner surface of the custom-fitted helmet can be formed by
an additive
process. Forming the inner surface of the custom-fitted helmet can be
accomplished by inserting
a liner comprising a plurality of contiguous pieces or a plurality of
separated pieces into a helmet
base unit. The liner can be formed as a substantially flat array of pieces and
a surface of the
substantially flat array of pieces can be adjusted to mirror the computerized
headform.
[0008] In another aspect, a method of making a custom-fitted helmet can
comprise
obtaining head data for a customer's head, comparing the head data to a helmet
safety standard,
and forming a custom-fitted helmet that satisfies the safety standard and
comprises an inner
surface comprising a topography that conforms to the head data for the
customer's head.
[0009] The method of making the custom-fitted helmet can further
comprise
obtaining bead data for the customer's head length, width, and at least one
head contour. A
graphical computerized 3D headform can be generated from the head data, the
helmet safety
standard can be provided as a graphical 3D helmet safety standard, and the 3D
headform can be
compared to the helmet safety standard by positioning the graphical 3D
headform within the
helmet safety standard to determine a size and shape of the inner surface of
the custom-fitted
helmet. The helmet safety standard can be a graphical 3D helmet safety
standard comprising a
certified surface. The graphical 3D helmet safety standard can comprise a test
line. A helmet
base unit can be selected to comprise a surface comprising a size and shape
different than a size
and shape of the inner surface of the custom-fitted helmet, and the inner
surface of the custom-
fitted helmet can be formed by removing EPS from the helmet base unit using a
CNC machine.
The helmet base unit can be formed comprising a first protective material and
a second
protective material disposed adjacent to the first protective material,
wherein the second
protective material is more easily removed that the first protective material,
and the custom-fitted
helmet can be formed by removing a portion of the second protective material.
The custom-
fitted helmet can be formed comprising posts configured to interface with a
jig to stabilize the
custom-fitted helmet during forming. The inner surface of the custom-fitted
helmet can be
formed by an additive process. The inner surface of the custom-fitted helmet
can be formed by
inserting a custom-fitted liner into a stock helmet. Head data for the
customer's head can be
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obtained by obtaining images of a deformable interface member disposed on the
customer's head,
wherein a thickness of the deformable interface layer corresponds to a
thickness of a padding layer
within the custom-fitted helmet.
[0010] In another aspect, a method of making a custom-fitted helmet
can comprise, at a
home or at a store, obtaining head data for a customer's head, and at a
location remote from the home
or retail store, forming a custom-fitted helmet that comprises an inner
surface comprising a
topography that conforms to the head data for the customer's head.
[00 11] The method of making the custom-fitted helmet can further
comprise obtaining
head data for the customer's head by obtaining images of a deformable
interface member disposed on
the customer's head, wherein the images comprise a marker of a known size. A
graphical
computerized 3D headform can be generated from the head data, a helmet safety
standard can be
provided as a graphical 3D helmet safety standard, and the 3D headform can be
compared to the
graphical 3D helmet safety standard by positioning the graphical 3D headform
within the graphical
3D helmet safety standard to determine a size and shape of the inner surface
of the custom-fitted
helmet. The graphical 3D helmet safety standard can comprise a certified
surface. The graphical 3D
helmet safety standard can further comprises a test line. Head data can be
obtained by obtaining a
length and a width of the customer's head based on two-dimensional (2D)
measurements. A helmet
base unit can be selected to comprise a surface comprising a size and shape
different than a size and
shape of the inner surface of the custom-fitted helmet, and the inner surface
of the custom-fitted
helmet can be formed by removing EPS from the helmet base unit using a CNC
machine. The
graphical 3D headform can be positioned within the graphical 3D helmet safety
standard to optimize
a field of view (FOV) for the customer.
According to another aspect of the present invention, there is provided a
method of
making a custom-fitted helmet, comprising:
at a first location, scanning a customer's head to obtain_head data from a
customer's
head, said head data includes a length, a width, and at least one head
contour;
generating, with at least one computer, a computerized three-dimensional
headform
having an outer surface that matches the head data;
providing, with said computer, a three-dimensional helmet safety standard;
comparing, with said computer, the outer surface of the three-dimensional
headform
to a three-dimensional_helmet safety standard; and
Date Re9ue/Date Received 2021-04-09
when said three-dimensional helmet safety standard is satisfied, forming the
custom-
fitted helmet at a second location different from the first location, wherein
the custom-fitted
helmet has an inner surface with a topography that conforms to the length,
width, and at least
one contour of the head data.
According to another aspect of the present invention, there is provided a
method of
making a custom-fitted helmet, comprising:
obtaining head data from a customer's head;
providing, with a computer, a helmet safety standard that includes a certified
surface;
comparing, with said computer, the head data to the certified surface of the
helmet
safety standard to assess whether the obtained head data extends through the
certified
surface; and
when said head data does not penetrate the certified surface, forming the
custom-
fitted helmet with an inner surface having a topography that conforms to the
head data for the
customer's head.
According to another aspect of the present invention, there is provided a
method of
making an internal padding assembly for a custom-fitted helmet, comprising:
at a home or at a store, obtaining head data from a customer's head; and
generating, with at least one computer, a graphical headform having an outer
surface
that matches the head data;
providing, with said computer, a graphical helmet safety standard;
positioning, with said computer, the graphical headform within the graphical
helmet-
safety standard in order to satisfy the graphical helmet-safety standard; and
when said graphical helmet safety standard is satisfied, forming, at a
location remote
from the home or retail store, the internal padding assembly of the custom-
fitted helmet,
wherein the internal padding assembly has an inner surface with a topography
that conforms
to the head data for the customer's head.
According to another aspect of the present invention, there is provided a
method of
making a custom-fitted protective helmet, comprising:
obtaining head data from a customer's head;
generating, with at least one computer, a graphical 3D headform having an
outer
surface that matches the head data;
providing, with said computer, a graphical 3D helmet safety standard that
includes a
graphical 3D certified surface;
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comparing, with said computer, the outer surface of the graphical 3D headform
with
the graphical 3D certified surface; and
when said outer surface of the graphical 3D headform does not extend into the
graphical 3D certified surface, forming the custom-fitted protective helmet
with an inner
surface having a topography that conforms to the head data for the customer's
head.
According to another aspect of the present invention, there is provided a
method of
making an internal padding assembly for a custom-fitted protective sports
helmet, comprising:
obtaining head data from a customer's head;
generating, with a computer, a headform having an outer surface that matches
the
head data;
providing, with said computer: (i) a helmet safety standard that includes a
certified
surface and (ii) a minimum dimension that extends between an extent of a
computerized
helmet and the certified surface;
determining, with said computer, an actual distance defined between the extent
of the
computerized helmet and the outer surface of the headform; and
when the actual dimension is greater than the minimum dimension, forming the
internal padding assembly of the custom-fitted helmet, wherein an inner
surface of the
internal padding assembly has a topography that conforms to the head data for
the customer's
head.
According to another aspect of the present invention, there is provided a
method of
making an internal padding assembly for a custom-fitted protective helmet,
comprising:
obtaining head data from a customer's head;
generating, with a computer, a headform that has an outer surface that matches
the
head data;
providing, with said computer, a helmet safety standard that includes a
certified
surface;
comparing, with said computer, the outer surface of the headform to the
certified
surface; and
when the outer surface of the headform does not extend past the certified
surface,
using an additive manufacturing process to form an extent of the internal
padding assembly
of the custom-fitted helmet, wherein an inner surface of the internal padding
assembly has a
topography that conforms to the head data for the customer's head.
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According to another aspect of the present invention, there is provided a
multi-step
method of designing an energy attenuation layer for a custom-fitted protective
helmet, comprising:
obtaining head data from a customer's head using a scanning device;
processing the head data to create a three-dimensional digital model of the
customer's head;
providing a three-dimensional digital model of a safety standard;
positioning the three-dimensional digital model of the customer's head within
the
three-dimensional digital model of the safety standard;
comparing the three-dimensional digital model of the customer's head with the
three-dimensional digital model of the safety standard to assess whether the
safety standard
is satisfied; and
when said the safety standard is satisfied, creating a computerized model of
the
energy attenuation layer that is (i) configured to be inserted within a helmet
shell and (ii) has
an inner surface with a topography that conforms to the three-dimensional
digital model of
the customer's head.
According to another aspect of the present invention, there is provided a
multi-step
method of designing an energy attenuation layer for a custom-fitted protective
helmet, comprising:
obtaining head data of a customer's head;
processing the head data to create a three-dimensional digital model of the
customer's head;
providing a three-dimensional digital model of a safety standard with a
certified
surface;
comparing the three-dimensional digital model of the customer's head with the
three-dimensional digital model of the safety standard to determine whether
the three-
dimensional digital model of the customer's head extends through the certified
surface; and
when the three-dimensional digital model of the customer's head does not
extend
through the certified surface, creating a computerized model of the energy
attenuation layer
that (i) is configured to be inserted within a helmet shell and (ii) has an
inner surface with a
topography that conforms to the three-dimensional digital model of the
customer's head.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 shows a mechanical measurement tool.
[0013] FIGs. 2A-2C show an embodiment of a customer wearing a
deformable interface
member.
[0014] FIGs. 3A-3B show another embodiment of a customer wearing a
deformable
interface member.
[0015] FIGs. 4A-4C show a 3D headform generated by modeling software.
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[0016] FIGs. 5A-5C show head data being compared to a helmet safety
standard for
forming a custom-fitted helmet.
[0017] FIGS. 6A-6F show a custom-formed helmet, a headform and a
helmet safety
standard.
FIGs 7A-7D show forming a custom-fitted helmet including a finished inner
surface comprising a topography that matches a customer's head.
[0018] FIGs. 8A and 8B show another embodiment of a custom-fitted
helmet.
[0019] FIGs. 9A and 9B show other embodiments of a custom-fitted
helmets.
[0020] FIGs. 10A and 10B show other embodiments of a custom-fitted
helmets.
DETAILED DESCRIPTION
[0021] This disclosure, its aspects and implementations, are not
limited to the specific
helmet or material types, or other system component examples, or methods
disclosed herein. Many
additional components, manufacturing and assembly procedures known in the art
consistent with
helmet manufacture are contemplated for use with particular implementations
from this disclosure.
Accordingly, for example, although particular implementations are disclosed,
such implementations
and implementing components may comprise any components, models, types,
materials, versions,
quantities, and/or the like as is known in the art for such systems and
implementing components,
consistent with the intended operation.
[0022] The word "exemplary," "example," or various forms thereof are
used herein to
mean serving as an example, instance, or illustration. Any aspect or design
described herein as
"exemplary" or as an "example" is not necessarily to be construed as preferred
or advantageous over
other aspects or designs, Furthermore, examples are provided solely for
purposes of clarity and
understanding and are not meant to limit or restrict the disclosed subject
matter or relevant portions
of this disclosure in any manner. It is to be appreciated that a myriad of
additional or alternate
examples of varying scope could have been presented, but have been omitted for
purposes of brevity.
[0023] While this disclosure includes a number of embodiments in many
different
forms, there is shown in the drawings and will herein be described in detail
particular embodiments
with the understanding that the present disclosure is to be considered as an
exemplification of the
principles of the disclosed methods and systems, and is not intended to limit
the broad aspect of the
disclosed concepts to the embodiments illustrated.
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[0024] This disclosure provides a system and method for custom
forming a
protective helmet for a customer's head, such as a helmet for a cyclist,
football player, hockey player,
baseball player, lacrosse player, polo player, equestrian rider, rock climber,
auto racer, motorcycle
rider, motocross racer, skier, skater, ice skater, snowboarder, snow skier and
other snow or water
athlete, sky diver or any other athlete in a sport or other person including
soldier, pilot, or other
military person, who is in need of protective head gear. Each of these sports
uses a helmet that
includes either single or multi-impact rated protective material base that is
typically, though not
always, covered on the outside by a decorative cover and includes comfort
material on at least
portions of the inside, usually in the form of padding. Other sports, such as
boxing sparring,
wrestling and water polo use soft helmet types. Soft helmet types can also
benefit from particular
aspects of the disclosed methods and system through custom fit soft helmets.
Other industries also
use protective headwear, such as a construction, soldier, fire fighter, pilot,
or other worker in need of
a helmet, where similar technologies and methods may also be applied. The
method, system, and
devices described herein are discussed with particular reference to heads and
custom-fitted helmets,
the same or similar methods, systems, and devices are applicable to other body
parts and
corresponding gear or clothing.
[0025] Human heads are each very different. Even if two people
have the same head
circumference, they may have different relative length and width measurements,
and certainly have
different head topographies. Conventional helmet sizes, small, medium, large,
extra large, etc., are
generally based on bead circumference. If a customer's head circumference is a
particular
circumference, the customer may try a particular generic helmet size that does
not fit because the
customer's head is longer or wider than "normal," and is different from the
generic helmet size, such
that the customer may try wearing the next larger generic helmet size.
However, the customer's head
may have had a head shape that includes a width that is substantially equal to
a first or generic small
width, while the customer's head further includes a length that is
substantially equal to a second or
generic medium length. in a such a situation, putting the customer into a
medium sized helmet results
in the helmet not fitting as well as it could because the helmet width is now
too big and must be filled
by extra padding. By studying many different head shapes and the fit of
helmets to those respective
head shapes, it has been discovered that head length and width are the most
important measurements
on a head in determining a comfortable fit and providing a good match between
a customer's head
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Date Recue/Date Received 2020-08-31
topography and a topography of the helmet It has also been discovered that
matching a length and
width of a customer's head to a length and width of the customer's helmet is
more important than
only matching a circumference of the customer's head to a circumference of the
customer's helmet.
Additionally, matching a topography of the customer's head to a topography of
the customer's helmet
also plays a significant role in determining a good fit for comfort. As
additional data on more and
more head shapes and topography continues to be gathered and studied,
additional classifications of
head shapes may be discovered to further refine the processes described
herein.
[0026] Accordingly, this disclosure relates to a system for
manufacturing a customer
specific custom-fitted helmet that matches a customer's particular head size
and topography to a
helmet that is created specifically for that customer. The system may be
implemented through a
computer interface or other method that receives the customer's head data and
then manufactures a
custom-fitted helmet unique to that customer's head data. As an overview, a
particular non-limiting
embodiment comprises receiving captured customer head data, analyzing the
received data for
comparison with safety standards, a pre-determined thickness or other
standards, creating an
acceptable 3D model for at least portions of the helmet internal surface, and
creating a custom helmet
specific to the customer's data received.
[0027] A protective helmet customer's head data may be gathered in a
variety of
different levels of detail and manners. Particular embodiments of the systems
and methods disclosed
are improved and more useful with more data received, but the systems and
methods are not limited
to capturing the full level of detail in every instance. For example, although
capturing a full 3D
model and topographical layout of a customer's head may be accomplished using,
for example, a
non-contact or optical sensor such as a laser, an optical micrometer,
photographic camera, or video
recorder, in many cases just the customer's head length and head width
measurements may be used to
create a custom helmet for the customer through embodiments of the system and
method. It is
intended that although particular more complete levels of data capture are
described herein, any of
the embodiments may be implemented with any level of data capture detail by
either substituting in
standard data for any missing data, or by comparison with other similar head
shapes to customize to
the most likely head topography for the customer from other customer data with
acceptable margins.
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[0028] Customer head data may be captured with the customer present
through the
use of mechanical measurement tools such as a ruler, tape measure, or
calipers, or through
optical tools such as a 2D photo or series of photos or video that can later
be broken down by
frames to extract the data, through physical casting of the customer's head,
through laser
micrometers, touch probes, magnetic resonance imaging, CT scanning, radio wave
scanning,
micrometer scanning of the customer's head or portions of the customer's head,
and any other
method known for gathering measurement data relating to the outer surface of
the customer's
head. Those of ordinary skill in the art will readily understand how to
extract the data into a
usable form from the particular data gathering method chosen. FIG. 1 shows an
exemplary two-
dimensional head measurement tool 10 that includes a ruler 12, a slidable
member 14, and pads
16, configured to be disposed against a customer's head or in contact with
another body part or
object to be measured. By adjusting slidable member 14 until pads 16 are
touching, or adjacent
to, opposing portions of a customer's head or other body part, an accurate 2D
distance can be
obtained.
[0029] FIGs. 2A-2C show a particular, non-limiting example of how
biometric data
of a customer 20 may be captured and received from a customer wearing a
deformable interface
member 22 for a custom fit helmet. Deformable interface member 22 comprises a
flexible sleeve
or tube that can be made of a thin, resilient, radially stretchable material
designed to conform and
contour to at least a portion of customer 20. Deformable interface member 22
can comprise a
loose-knit fiber breathably configured to allow airflow during use. Providing
breathable
configurations of deformable interface member 22 can be of particular benefit
when the
deformable interface member is disposed over a face of customer head 30.
Deformable interface
member 22 can be formed of a fiber or loose-knit fiber or material that can be
any one of a
number of stretchable or elastic materials, including NYLON, LYCRA, SPANDEX,
BIOSKIN,
EpX, or other suitable commercially available material.
[0030] FIG. 2A shows customer 20 wearing a deformable interface member
22 that is
configured as a tight fitting cap or head piece 26 disposed over a portion of
customer head 30.
Cap 26 can be disposed over the customer's crown and a top portion of customer
head 30
without covering an entirety of customer head 30 including the face of
customer 20. The portion
of customer head 30 covered by cap 26 can correspond to a portion of customer
head 30 that will
be covered by the customer's custom-fitted helmet. In some instances, a size
of the portion of
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customer head 30 covered by the deformable interface member 22 will be equal
to or greater
than a size of a portion of customer head 30 that will be covered by the
customer's custom-fitted
helmet.
[00311 For the measurement of most heads, by wearing a deformable
interface
member 22, at least a portion of the customer's hair 32 can be pressed flat
against customer head
30. Because most customers have some hair, and at a minimum the deformable
interface
member 22 has a thickness, even when deformable interface member 22, such as
cap 26 is
designed to fit tightly on customer head 30, a gap or offset will exist
between a surface of
customer head 30 (such as the scalp) and an outer surface 34 of deformable
interface member 22.
In most if not all cases, margins of error for the gap between the surface of
customer head 30 and
the outer surface 34 of deformable interface member 22 is small enough to not
be critical to the
processes for creation of a custom helmet. More specifically, a thickness of
the customer hair 32
under the deformable interface material is often a good approximation of a
thickness of customer
hair 32 that will be accommodated between customer head 30 and an inner
surface of the
customer's customized helmet. Alternatively, a known or approximate thickness
of the
deformable interface member 22, a thickness of the customer's hair 32, or both
can be subtracted
from a measurement of the outer surface of deformable interface material 22 to
produce a better
approximation of an actual measurement of customer head 30.
100321 In an embodiment, a thickness of deformable interface material 22
can be
selected to be equal to a thickness of subsequently added comfort padding.
Thus, deformable
interface material 22 can provide a desired offset for subsequently included
comfort padding,
such as padding of interface layer 84, without a need for performing costly
post-measurement or
post-processing computer aided drafting (CAD) work. By directly measuring a
good and viable
approximation for a surface 85 of padding 84, an amount of expensive CAD work
needed for
generating a custom inner surface 82 of a custom-fitted helmet 81 is reduced,
thereby providing a
streamlined and cost-effective process for modeling and generating custom-
fitted helmets 81.
Accordingly, any gap between the scalp of a customer head 30, including
customer hair 32 and a
thickness of deformable interface member 22, can be accounted for in a variety
of ways
according to the application and design of the modeling process. For
convenience of discussion,
the present disclosure will at times refer to the head data gathered from an
outer surface of
deformable interface material 22 as the customer's head data relevant to the
surface of the
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customer head 30, and not as an approximation. However, the measurement of
customer head 30
can also include an offset for padding 84.
[0033] In a particular embodiment, cap 26 used for the initial
measurements of
customer head 30 comprises a thickness of approximately 1.5 mm (made of
neoprene in
particular embodiments). It has been found that for some wearers, like track
racers, a tighter fit
is more desirable than for other wearers, like street riders, who are used to
a looser fit on their
head. In particular embodiments described below, the surface of the 3D
headform 66 is used as
the cutting surface for the customization process for the inner surface of the
base unit. In other
embodiments, additional calculations are made to virtually add a layer between
the wearer's head
and the cut surface before the cut surface is defined and the cuts are made.
By having the wearer
wear a cap that includes a predetermined thickness that is chosen to allow a
particular offset
between the wearer's head and the internal surface of the final custom helmet,
the additional
calculations are not needed. This reduces processing time and significantly
simplifies the cutting
surface calculations.
[0034] In one particular embodiment, three different cap thicknesses are
used as
options for a wearer depending upon the wearer's preferences and the ultimate
purpose for the
helmet created. In a particular embodiment, a first cap thickness is 1.5 mm, a
second cap
thickness is 3.0 mm and a third cap thickness is 4.5 mm. These examples are
non-limiting and
user preferences are different and uses for the helmets are different so that
any range of cap
thicknesses and any number of caps is contemplated for use with various
embodiments. In
another particular embodiment, instead of, or in addition to, separate caps
being used, a wearer
may apply multiple caps simultaneously to obtain a thicker offset. For
example, a wearer may
apply three 1.5 mm caps to obtain a cap thickness of 4.5 mm. Thus, a wearer
may indicate a
preference as to how tight they want their final helmet to fit and without
requiring additional
complex calculations the system can automatically adapt the final cut line
helmet model to
compare with the headform by simply applying a particular thickness of cap or
multiple caps of
the same or different thicknesses during data capture.
[0035] in other particular embodiments, the cap thickness may be
selected to
automatically establish a padding offset or the padding offset combined with a
comfort offset,
without the system further calculating a 3D offset from the wearer's measured
head data. By
incorporating the offset into the cap thickness, the offset that ordinarily
would have been
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calculated by the computer system may be automatically accounted for through a
thicker cap.
Provided the cap material fits closely to the wearer's head, like neoprene or
nylon or another
elastic and flexible, form fitting material, this method may be used to
establish the desired offset
without further calculating of a separate cutting surface.
[0036] As shown in FIGs. 2A-2C, cap 26 includes a reference or grid
pattern 28
comprising horizontal and vertical lines. However, reference pattern 28 can
comprise vertical
lines, skewed lines, intersecting lines, bars, squares, circles, diamonds,
hatching, or any
geometric pattern, organic pattern, stochastic pattern, or any other design of
suitable shapes,
colors, patterns, or forms. As illustrated in FIGs. 2A-2C, the horizontal
lines may be further
configured as major horizontal reference lines 36 and minor horizontal
reference lines 38
separated by known distances. For example, FIG. 2A is a side view of customer
head 30
wearing cap 26 that includes, in an embodiment, three major horizontal
reference lines 36
formed around circumferences of differing sizes along interface member 22.
FIG. 2.A
additionally shows a plurality of minor horizontal reference lines 38 spaced
at known or even
intervals that can be spaced at a fixed distance between each of the major
reference lines 36. In
an embodiment, as illustrated in FIG. 2A, 5 minor reference lines 38 are
disposed between each
adjacent pair of major reference lines 36, although any number of reference
lines can be used. In
addition, interface member 22 can also include vertical reference lines 40
that are perpendicular
or normal to the horizontal reference lines. As shown in FIG. 2C, a top view
of cap 26 is shown
in which interface member 22 includes a first vertical reference line 40a
extending between front
and back portions of customer head 30 in a direction of a length L of the
customer head.
Similarly, interface member 22 is also shown including a second vertical
reference line 40b
extending between opposing sides of customer head 30 in a direction of a width
W of the
customer head, in which the vertical reference line 40a intersects vertical
reference line 40b at a
perpendicular angle, or an angle of approximately 90 degrees. Therefore,
reference lines 36, 38,
and 40 form an exemplary reference pattern 28 that can show a shape, contour,
or topography of
customer head 30, and can be used in collecting data for the customer head,
including length,
width, and at least one contour of the customer head. For example, vertical
line 40a can follow
and delineate a contour of customer head 30 along a peak or ridge of the
customer head along its
length. Similarly, vertical reference line 40b can follow and delineate a
contour of customer
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head 30 along a peak or ridge of the customer head along its width.
Additionally, a plurality of
other contour lines can also be captured by any number of different reference
patterns 20.
[00371 As shown
in FIGs. 2A and 2B, cap 26 can also include measurement points
42. Deformable interface member 22 can include any number of measurement
points, and in an
embodiment, includes at least four measurement points 42 located on a left
side, right side, front
and rear portion of deformable interface member 22 and in-line or overlapping
with vertical
reference lines 40a and 40b. Deformable interface member 22 can further
include an orientation
device 44 that may be located at an uppermost extent of deformable interface
member 22 or at an
intersection of vertical reference lines 40. Orientation device 44 helps
facilitate imaging of
deformable interface member 22, such as by photographs, and can further
facilitate subsequent
compilation or assimilation of the images to provide a comprehensive data set
or headform of
customer head 30, as discussed in greater detail below. Orientation device 44
can be sized and
shaped in any suitable configuration and material. For example, orientation
device 44 can be
configured as one or more plastic tubes formed into any shape to provide
relative orientation
between deformable interface member 22 and customer head 30.
[0038] Thus, a
non-limiting example of a particular method for obtaining head data
can be understood with respect to FIGs. 2A-2C. First, customer 20 wears cap 26
on customer
head 30. Next, an initial set of reference measurements are taken of
measurement points 42
while customer 20 is wearing an interface member 22 such as cap 26. For
example,
measurements can be taken along vertical reference lines 40a and 40b from the
front, rear, left,
right, and top sides of deformable interface member 22. The method can further
include
orientation device 44 aligned with deformable interface member 22 when
measuring the
deformable interface member. The measurement of deformable interface member 22
can be
done directly with the interface member, such as by using head measurement
tool 10, or other
suitable 2D or 3D measurement tool, or by taking a plurality of photographs of
the interface
member while worn on customer head 30. Photographs can be taken of left,
right, front, rear,
and top views of the customer's head, including measurement points 42 and
orientation device
44. Measurements can also be made of customer head 30 by collecting data from
the
photographs or from a 3D headform or model that is constructed from the
customer head data.
Because cap 26 can include major horizontal reference lines 36, minor
horizontal reference lines
38, vertical reference lines 40, measurement points 42, and orientation device
44, more data can
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be gathered during imaging for determining a more complete model of the
topography of customer
head 30.
[0039] FIGs. 3A and 3B show another variation of a method for
obtaining consumer
head data for customer 20 wearing a deformable interface layer 22. More
specifically, FIG. 3A
shows a front view of customer 20 wearing a deformable interface member 22
configured as a tight
form fitting headpiece or mask 50 disposed over an entirety of customer head
30 and the customer's
face, which facilitates obtaining head data for an entirety of the customer
head 30. Obtaining head
data for an entirety of customer head 30 can be obtained, as described above,
by use of one or more
mechanical measurement tools, optical tools, or both. As a non-limiting
example, head data can be
obtained for customer head 30 while wearing headpiece 50 by capturing photos
of customer head 30.
Photographs or images of headpiece 50 can be obtained for multiple views and
from multiple angles
relative to customer head 30. A greater number of photos can capture a greater
amount of detail of
customer head 30 such that a better custom fit for a custom-fitted helmet can
be possible. In an
embodiment, five images or photographs are taken of a customer's head 30
wearing deformable
interface member 22, the five images including a front view, a back view, a
left view, a right view,
and a top view.
[0040] As shown in FIG. 3A, a width (W) of customer head 30 can be
measured by
taking a distance from opposing outer edges of customer head 30 in the coronal
plane. As shown in
FIG. 3B, a length (L) of customer head 30 can be measured by taking a distance
from opposing outer
edges of customer bead 30 in the sagittal plane. Thus, a length L and width W
of customer head 30,
as well as a general shape of customer head 30, can be obtained by imaging
customer head 30.
Additionally, contours of customer head 30 can also be obtained. Exemplary
contours can include a
first contour 54 that includes a crest or ridgeline along a peripheral edge of
customer head 30 as seen
in FIG. 3A or a second contour 56 that includes a crest or ridgeline along a
peripheral edge of
customer head 30 as seen in FIG. 3B. A plurality of other contours can also be
obtained for different
crests and ridgelines along a peripheral edge of images or photographs taken
at different relative
angles with respect to customer 20. A greater number of contours can provide a
greater amount of
detail of the shape and topography of customer head 30 such that a better
custom fit for a custom-
fitted helmet can be possible.
[0041] As shown in the front view of FIG. 3A and the side view of FIG.
3B, headpiece
50 does not include a reference or grid pattern such as the reference pattern
28 shown
14
Date Recue/Date Received 2020-08-31
in FIGs. 2A-2C. Instead a marker or reference item 52 is used to indicate
relative size of customer
head 30 and facilitate scaling of dimensions from the captured images or
scans. As such, marker 52
comprises known dimensions, and can include a fixed feature positioned
adjacent to the customer
when the customer wearing headpiece 50 is imaged or the head data is obtained.
Marker 52 also
comprises movable items that can be held or positioned by customer 20 for
imaging. For example,
FIG. 3A shows customer 20 holding a coin as marker 52 to provide a relative
distance or scale for
measuring or calibrating the head data obtained from imaging headpiece 50.
Thus, by including
marker 52 within a photograph of customer 20 wearing headpiece 50 taken at a
first location, the
relative dimensions of head 30 can be analyzed at a time after the photo is
taken, and at a second
location that is different or remote from the first location.
[0042] For example, the first location can be at a home or residence,
such as the
customer's home, where customer head data collection can be obtained, for
example, through
imaging, measuring, or photographing in the convenience of the home of
customer 20.
Additionally, the first location can also include a store, kiosk, tradeshow,
or other event or
location at which images or data of customer head 30 can be captured. When
capturing head
data at the first location, customer 20 or another individual assisting the
customer can take or
capture one or more photographs with a discrete or stand alone camera.
Alternatively, one or
more photographs can be captured by a camera that is integrated with a
computer, tablet, or
handheld electronic device. The integrated camera can also be associated or
paired with an
application or software program that includes instructions or directions that
guide or prompt
customer 20 or other user or helper through a process of obtaining or
acquiring the appropriate
images of photographs. Interactive applications and software can also
adaptively adjust a
number and type of images taken in order to ensure adequate and proper data
for subsequent
helmet customization. For example, a stationary camera coupled to a computer
program can take
a series of photos at one or more fixed time intervals. The interactive
program can also prompt
the customer to position customer head 30 at useful positions for each image
captured, such that
the customer is directed to change their head position relative to the camera
during each time
interval to provide multiple pictures at different angles, such as pictures of
a front, side, and back
of customer head 30. Based on the quality of data received, the tolerance or
sizing required for a
final custom-fitted helmet, the interactive software can prompt customer 20 or
an assistant to
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take additional photographs or retake low quality and out-of-focus or
misaligned photographs to
ensure sufficient and proper head data is obtained to make the custom-fitted
helmet. The
interactive application can also be configured to enable the customer to
select other
customizations for the custom-fitted helmet.
[0043] The head data obtained for customer 20 need not be restricted to
a single use
or customized-fitted helmet. Instead, the data gathered for customer 20 can be
entered into
database 24 and used to establish a customer profile for later processing,
analysis, and
manufacture. Because, after a particular age, a shape and size of customer
head 30 will not
change significantly, the customer's profile may be saved for some time and
used for future
custom helmet orders. Updating head data for customer 30 can occur at regular
or fixed intervals
based on the customer's age, the customer's anticipated growth, or in
conjunction with athletic
seasons and schedules. For example, a customer's head data can be updated at
least every year,
or at least every six months by measuring at least one or more of the
customer's updated head
length, updated head width, or updated head contour.
[0044] Thus, customer head data, once captured, and before or after
refinement of the
data, can be sent from the first location to a second location remote from the
first location. The
customer head data may be transmitted to database 24 in which head data is
centralized for
further processing, analysis, and manufacture of a custom helmet, as discussed
in greater detail
below. The data may be transferred in any way to database 24 such as, but not
limited to, entry
into and transmission through a computer over the Internet or other
transmission method, mailing
the data records, or a store employee, customer assistant or even the customer
calling someone
associated with database 24 and relaying the data.
100451 FIGs. 4A-4C show that after obtaining head data for customer 20,
the head
data can be used to generate a computerized 3D headform matching a length,
width, and head
contour of customer head 30 using at least one processor and a 3D modeling
program 60. Before
the computerized 3D headform is generated, the customer's head data can be
further processed,
if needed, and analyzed for the specific measurement data relevant to customer
head 30. For
embodiments where customer head data is captured as images, commercially
available image
analysis software can be used as 3D modeling program 60 to create an
approximate 3D image or
at least a 3D array of reference points for use in approximating the surface
of customer head 30.
FIG. 4A shows a non-limiting example of commercially available image analysis
software 62,
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123D Catch, which is produced by Autodesk, and can be used as a program for 3D
modeling.
Whether the surface data is modeled as a 3D solid, a 3D surface, a point
cloud, a data array, a
polygonal mesh, or any other surface model approximation method, the data may
be used to
approximate the surface of customer head 30 for purposes of this disclosure.
[0046] In an embodiment, head data for customer 20, such as photographs,
can be
imported into image analysis software 62 such that photographs of the customer
are placed on
corresponding reference planes, such as coronal, sagiftal, and transverse
planes, and are
dimensioned based on the measurements taken, such as the measurements from the
measurement
points 42 or from marker 52. 3D modeling program 60 generates a representation
of customer
head 30 and can include a 3D pattern that matches reference pattern 28, if
present. Accordingly,
3D lines can match major and minor horizontal reference line 40a and 40b,
respectively, as well
as vertical reference lines 40, if present, to each of the corresponding
reference planes. Using the
3D curves, the modeling program creates a surface that connects all of the
curves to form a 3D
headform or graphical representation 66 of the customer's head 30, as shown in
FIG. 413. 3D
headform 66 closely corresponds to a topography or the length, width, and at
least one contour of
customer head 30. Notably, 3D headform 66 can be offset by a predetermined
amount to
accommodate the thickness of the helmet's internal liner and/or internal
padding assembly.
[00471 FIG. 4B shows a 3D headform 66 for an upper or top portion of
customer
head 30 for forming a custom-fitted helmet that only covers the top portion of
customer head 30.
Alternatively, headform 66 can be for an entirety of customer head 30,
including the face, chin,
and neck, and be used for forming a custom-fitted helmet that covers only a
top portion of
customer head 30 or an entirety of customer head 30 including the face, chin,
and neck.
100481 As shown in FIG. 4C, graphical representation 66, including any
offset, can be
imported into a 3D tooling model 70 and points of the graphical representation
66 are aligned
with corresponding points of the tooling model. The headform of tooling model
70 can be made
to expose a shape of customer head 30. A headform may be created, such as by a
3D printer or
other method, to create a specific mold for use in creating a custom-fitted
helmet. Alternatively,
a helmet base unit may be sculpted to match the contours of customer head 30.
Either way, the
result is a custom-fitted helmet formed from the customer's 3D headform 66 to
provide a
custom-fitted helmet that is customized to the topography or the length,
width, and at least one
contour of customer head 30.
-17-
[0049] FIGs. 5A-5C show a comparison between 3D headform 66 and a
helmet safety
standard 71. 3D headform 66 can be used in an automated or graphic visual
comparison with helmet
safety standard 71 stored in association with processors associated with
database 24. In particular
embodiments, a protective base material can be disposed between an outer
surface 83 of custom-
fitted helmet 81 and a custom inner surface 82 of the helmet. Protective base
material 72 can be
formed of an energy absorbing material or energy attenuating material such as
EPS, expanded
polypropylene (EPP), plastic, foam, expanded polyethylene (PET), vinyl nitrite
(VN), polyurethane
(PU), ethylene-vinyl acetate (EVA), cork, rubber, orbathane, EPP/EPS hybrid
(Zorbium), EPLA,
brook foam, or other suitable material or blended combination or hybrid of
materials. Protective base
material 72 can protect customer 20 and customer head 30 through absorbing or
attenuating energy
during impacts by plastically or elastically deforming. In an embodiment, for
example, EPS foam can
be crushed during impact to protect customer head 30 during an impact.
Protective base material 72
can be provided in such a way as to ensure that protective base material 72
meets predetermined
minimum dimensions (Dm) as required by safety standard 71. Minimum dimensions
D 1 vr can be
specified by particular safety regulations or standards of the sport or
activity to which the helmet
applies, by particular manufacturing specifications or realities for
manufacture of the helmet, or by a
governing or regulatory bodies. Exemplary regulatory bodies and standards as
known by persons in
the art include three-dimensional helmet safety standards established by the
International Standards
Organization (ISO), the United Nations Economic Commission for Europe (ECE)
testing standards,
as commonly applied in Europe, the United States Depaitment of Transportation
(DOT), and the
Snell Memorial Foundation (a not for profit organization dedicated to
research, education, testing,
and development of helmet safety standards).
[0050] As shown in FIG. 5A, 3D headform 66 of customer 20 can be
automatically or
graphically compared to helmet safety standard 71, including minimum
dimensions DM, to
determine suitable sizing and dimensions for custom-fitted helmet 81. Based on
3D headform 66 and
minimum dimensions Dm, custom-fitted helmet 81 can be formed comprising a
custom inner surface
82c comprising a topography that conforms to the length, width, and at least
one contour of
customer head 30. As shown in FIG. 5B, actual dimensions (DA) as measured for
custom-fitted
helmet 81, are greater than or exceed the minimum dimensions Dm required by
helmet safety
standard 71. As shown in FIG. 5C, actual dimensions DA as measured for custom-
fitted
18
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helmet 81, can be greater than or equal to the minimum dimensions Dm required
by helmet safety
standard 71. In some instances, a first portion of custom inner surface 82c
can be formed such
that a thickness or distance between custom inner surface 82c and outer
surface 83 can be
substantially equal to or approximate a minimum dimension Dm required by
helmet safety
standard 71. As shown in FIG. 5C, the portion of custom inner surface 82c
disposed over a top
portion or crown of customer head 30 such that a thickness or distance between
custom inner
surface 82c and outer surface 83 is substantially equal to minimum dimension
Dm. Accordingly,
a second portion of custom inner surface 82c can be formed such that a
thickness or distance
between custom inner surface 82c and outer surface 83 is greater than a
minimum dimension DM
required by helmet safety standard 71, such as the portions of custom inner
surface 82c disposed
around a periphery or outside the top crown portion of customer head 30.
[00511 FIGs. 6A-6F, similar to FIGs. 5A-5C, show an embodiment in which
custom-
formed helmet 81 is compared against a helmet safety standard 71 that includes
more than a
minimum thickness of protective base material 72 to satisfy the helmet safety
standard. More
specifically, FiGs. 6A-6F show a method for establishing a test line or test
plane 73 for the
testing of custom-fitted helmet 81. Test line 73 can be derived from a
certified surface 77 rather
than from a custom formed custom inner surface 82 of helmet 81. As described
in greater detail
below, the establishment of test line 73 from certified surtke 77 can be done
graphically or
analytically with headform 66 of customer 20.
[00521 FIG. 6A. shows a cross-sectional view of a test headform 74. Test
headform
74 can be a tangible physical object or an analytical or computer model that
facilitates or allows
for virtual testing of physical helmets or models of helmets. When test
headform 74 is a virtual
helmet or model, the test headform can include a CAD file, or other suitable
computer file or
program. Test headform 74, whether physical or virtual, can be appropriately
sized, configured,
or made to posses or correspond to any attribute or requirement of helmet
safety standard 71.
Test headform 74 is configured to receive test helmets, such as helmet 78, and
facilitates testing
of the helmets to see if the helmets satisfy the relevant safety standards,
such as helmet safety
standard 71.
(00531 FIG. 6A further shows a helmet test line 73 formed on or
associated with test
headform 74 as an example of how a helmet safety standard 71 might be used in
testing a helmet
or non-custom-fitted helmet 78. A helmet 78, which is to be tested against
safety standard 71,
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can then be positioned on headform 74 and helmet test line 73 can then be
transferred from the
headform to an outer surface or shell of a helmet 78 for testing. During
testing, test line 73 is
used as a demarcation for indicating where helmet 78 can be subjected to
impacts during testing.
For example, tested helmet 78 may be subjected to impacts that are centered on
or above test line
73. Impacts used in the testing of helmet 78, or any helmet, occur at or above
test line 73 at a top
portion of a helmet because the top portion of the helmet is typically the
most important for
protecting user head 30, and impacts on a lower portion of helmet 78 below
test line 73 will
normally cause the helmet to fail. Test line 73 can be formed of any approved
or certified shape
in accordance with hehnet safety standard 71. As a non-limiting example, test
line 73 is shown
in FIGs. 6A.-6F as a typical test line approved or used by the Snell
Foundation.
[00541 As shown in FIG, 6A, test line 73 is transferred from. test
headform 74 to outer
surface 79 of helmet 78 so that a position or location of test line 73 is
formed on, or associated
with, helmet 78. The position of test line 73 on helmet 78 is based on a fit
between test
headform 74 and helmet 78. A relative position between test headform 74 and
outer surface 79
of helmet 78 can be established by using basic plane, Frankfurt plane, or
auricuolo-orbital plane
75 and a helmet positioning index (TIP!) relative to a point or plane of
helmet 78, such as upper
faceport edge 76 at a front of the helmet. Basic plane 75 is an anatomical
position of headform
74, a human skull, or customer head 30 defined by a plane passing through a
left orbitale (or the
inferior margin of the left orbit or eye-socket of the skull) and also passing
through the left and
right porions or the upper margins of each ear canal or external auditory
meatus. The IlPI
defines a distance between basic plane 75 of test headform 74 and a portion of
helmet 78, such as
a front portion of upper faceport edge 76 of helmet 78. HP1 can include any
suitable distance
based on the features and needs of a particular customer including distances
in a range 35-65
millimeters (mm), 40-55mm, or about 47mm.
{00551 Thus, in order to determine a location of test line 73 relative
to outer surface
79 of helmet 78 and which portions of helmet 78 will be subjected to impact
testing, the helmet
is positioned with respect to test headform 74 so that an outer surface of
test headform 74
"contacts" inner surface 80 of helmet 78. A front portion of a brow of
customer head 30 can be
placed in contact with a brow portion of inner surface 80 near an upper edge
of the faceport.
Helmet 78 can then be rotated so that a top or crown portion of customer head
30 is placed in
contact with a crown portion of inner surface 80. Helmet 78 can be positioned
with respect to
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test headform 74 by placing a physical or tangible helmet on a physical or
tangible headform,
although more commonly a graphical or analytical comparison is made using
computer
generated 3D images of the helmet and test headform. With helmet 78 on test
headform 74, test
line 73 is transferred from the headform to the helmet, thereby designating
the regions or
portions of the helmet that can be impacted during testing, for example on a
test rig.
[00561 When a mass produced helmet of standardized sizing and
standardized inner
surface is tested, such as helmet 78, the relative positions of headform 74
and any helmet 78
selected from the mass produced group will be substantially identical or
constant for all helmets
in a group because inner surface 80 for each helmet 78 is standardized and a
shape of headform
74 is constant. Accordingly, the relative position of test line 73 will also
be constant for each
and every helmet 78. A. constant relative position for test line 73 and helmet
78 allows for a
small representative number of helmets to be destroyed in testing to certify
that all helmets 78 of
a particular design satisfy the appropriate safety standards.
[0057] To the contrary, custom-fitted helmet 81 includes a custom inner
surface 82 of
protective base material 72, or an inner surface 85 of padding or interface
layer 84, such that
each custom-fitted helmet 81 can have a different relative position with
respect to test headform
74. Different relative positions between headform 74 and custom inner surface
82 potentially
result in a new position or location for each test line 73 transferred from
headform 74 to every
custom-fitted helmet 81. Under conventional testing standards, each custom
helmet would be
required to be produced in multiples so that a number of custom-fitted helmets
81 could undergo
destructive testing to ensure the design of a single custom-fitted helmet 81
worn by customer 20
satisfies the applicable safety standards. Because producing multiples of each
custom-fitted
helmet for destructive testing is not a commercially viable approach for
producing and selling
custom-fitted helmets, non destructive testing including analytically or
graphically comparing a
custom-fitted helmet 81 with a helmet safety standard 71 can be used. As a non-
limiting
example, an alternative method for testing custom-fitted helmets 81 is shown
in FiCis. 6B-6F and
discussed below.
[00581 FIG. 6B shows a certified surface 77 for locating test line 73 on
outer surface
83 of custom-fitted helmet 81 as part of a method for testing custom-fitted
helmets. Certified
surface 77 is generated and approved as part of helmet safety standard 71, and
can be fixed with
respect to outer surface 83 of custom-fitted helmet 81 to ensure a minimum
thickness of
-21-
protective base material 72 is used as part of the custom-fitted helmet. While
certified surface 77
can be coextensive with an inner surface of protective base material 72 or
coextensive with an inner
surface 82 of custom-fitted helmet 81, certified surface 77 can also be
different than inner surface 82
as discussed in greater detail with respect to FIG. 6C.
[0059] FIG. 68, in contrast to FIG. 6A, shows a cross sectional view
of test headform 74
within custom-fitted helmet 81 instead of non-custom fitted helmet 78. FIG. 6B
also shows, in
addition to certified surface 77, inner surface 85 of padding or interface
layer 84. Padding layer 84
can be disposed between protective base material 72 and headform 74 or 30
headform 66. Padding
laver 84 can be a comfort layer of foam, padding, or other suitable material
that can be softer or more
deformable than protective base material 72. Padding layer 84 can be of any
thickness, and in an
embodiment, has a thickness in a range of 0-20 mm, 1-10 mm, or about 5 mm.
Inner surface 85 is
the surface of padding layer 84 that is closest to customer head 30, 3D
headform 66, or headform 74.
Thus a location, position, and contour of surface 8.5 of padding layer 84 can
be determined and
controlled by adding a distance or offset, representing a thickness of padding
layer 84, to the
topography or contours of inner surface 82 of custom-fitted helmet 8.1. The
distance or offset can
be constant for an entirety of padding layer 84 when a thickness of padding
layer 84 is uniform and
constant. Alternatively, the distance or offset can be variable or changing
for at least a portion of
padding layer 84 when a thickness of padding layer 84 is non-uniform or
variable.
[0060] Certified surface 77 can be generated or selected based on data
from numerous
customer heads 30, including 3D headforms 66. By taking a group or set of head
data for similarly
sized heads, a certified surface 77 can be generated that would accommodate
each of the heads
included within the data set. Certified surface 77 does not need to exist
physically, as a tangible
stmcture within custom-fitted helmet 81 or as part of a helmet base unit 86,
but can exist
mathematically, graphically, or as part of a model. In an embodiment, for
example, certified surface
77 exists as part of a computer executable program such as a piece of CAD
software, and can be used
for defining or generating test line 73.
[0061] Advantageously, certified surface 77 can be used for
positioning headform 74
within custom-fitted helmet 81 or base unit 86 and transferring test line 73
from the headform to
outer surface 83 of the custom-fitted helmet. In order to transfer test line
73 from headform 74 to
outer surface 83 of the custom-fitted helmet, the test headform can be
positioned in an
22
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uppermost and forwardmost position permitted by certified surface 77 (or
another relative
position or offset defined by certified surface 77 such as surface 85 of
padding 84, which is
referred to herein for convenience as the certified surface). As such, helmet
81 can be positioned
with respect to test headform 74 so that an outer surface of test headform 74
aligns or is
coextensive with certified surface 77. More specifically, a front portion of a
brow of head form
74 can be aligned with a brow portion of certified surface 77 near an upper
edge of the faceport.
Helmet 81 can then be rotated so that a top or crown portion of headform 74 is
aligned with a
crown portion of certified surface 77, while also maintaining alignment with
the brow portions.
[00621 Helmet 81 can be positioned with respect to test headform 74 by
placing a
physical or tangible helmet on a physical or tangible headform, although more
commonly a
graphical or analytical comparison is made using computer generated 3D images
of the helmet
and test headform. By aligning headform 74 toward the front and top portions
of custom-fitted
helmet 81, a gap, offset, or some space can exist between a rear portion of
headform 74 and a
rear portion of certified surface 77, especially for headfomis of varying
sizes including larger
sizes. The gap can be filled with protective base material 72 by the formation
of custom inner
surface 82 based on a specific size or shape of an actual customer head 30 or
3D headform 66, as
discussed below in relation to FIG. 6C. After test headform 74 is positioned
within helmet 81,
test line 73 is then transferred from test headform 74 to outer surface 83 of
custom fitted helmet
81. In other words, a projection of test line or test plane 73 can be extended
outwards until it
contacts or intersects with outer surface 83 of custom-fitted helmet 81 and an
actual mark, or a
set of coordinates or data is noted or saved relative to outer surface 83 to
identify which regions
or portions of custom-fitted helmet 81 can be subsequently impacted during
impact testing. In an
embodiment, the test line 73 and the HPI are only used for certification
purposes with the
certified surface and certified headform. The certified headform 74 shows
drawing a test line 73
can be done in a repeatable manner and therefore any custom 3D headform 66
would follow the
same established test line 73 from an original certification.
[00631 FIG. 6C shows a cross-sectional view of 3D headform 66, rather
than test
hcadform 74, disposed within custom-fitted helmet 81 comprising test line 73.
FIG. 6C also
shows how additional base material 72 can extend beyond, or be added to,
certified surface 77 to
provide custom inner surface 82 that can include a topography that conforms to
a length, width,
and at least one contour of 3D headfonn 66 or customer head 30 that is closer
to 3D headform 66
-23-
than certified surface 77 is to the 3D headform. Custom inner surface 82 can
also take into account,
or include an offset for, padding or interface layer 84. Accordingly, a custom
inner surface 82 of
custom-fitted helmet 81 can include surface 85 of padding layer 84 as shown in
FIGs. 6C-6F.
Advantageously, 3D headform 66 can be positioned within custom-fitted helmet
81 and within
certified surface 77 in such a way as to optimize a fit of customer head 30
within custom-fitted
helmet 81 and to optimize a field of view (FOY) for customer 20. Additionally,
3D headform 66
can be positioned within custom fitted helmet 81 by aligning or matching the
brow portion of
headform 66 with the brow portion of custom inner surface 82 of custom fitted
helmet 81 while also
aligning crown portions of the 3D headform and custom inner surface.
[0064] By considering a position of an eye of customer 20 when
positioning 3D
headform 66 within custom fitted helmet 81, the FOV for customer 20 can be
increased. In an
embodiment, the eye of customer 20 can by aligned with a faceport of custom-
fitted helmet 81 by
adjusting a vertical offset or distance between the eye of the customer and
the upper faceport edge
76, or the lower faceport edge, so that the edge of the faceport does not
obstruct the customer's
vision. Optimal eye position within the faceport can vary by application. For
example, when
maximizing customer FOV, a lower position of the faceport relative to a
customer's eye is desirable
for upright street riding, while a higher position of the faceport relative to
a customer's eye is
desirable for aggressive tucked race positions where a relative location of
upper faceport edge 76 is
an important constraint for visibility.
[0065] Additionally, a distance between the eye of customer 20 can
also be moved
closer to the faceport of custom-fitted helmet 81. In conventional or stock
helmet designs, a
user's head is centered front to back within the helmet and can produce a
significant offset
between a front of the helmet and the front of customer head 30. As a result
of the offset
between the user's eye and the front of the helmet, edges of a helmet faceport
can obscure more
of the user's FOY. On the other hand, by orienting customer head 30 the
farthest forward
permissible by applicable safety standard 71, FOV can be improved for customer
20 by reducing
an amount of obstrnction created by faceport edges of custom-fitted helmet 81.
Gains achieved
by moving a customer's head farther forward can also be greater for those
customers that have
heads that arc shorter front to back. Applicants have discovered that even
small changes in
distances between the eye of customer 20 and a front of the helmet, or
vertical distances between
24
Date Recue/Date Received 2020-08-31
the customer's eye and the upper and lower edges of the helmet faceport, can
have significant effects
on the area of the customer's FOY.
[0066] Once 3D headform 66 is properly aligned within custom-fitted
helmet 81,
unwanted gaps or spaces between certified surface 77 and the 3D headform can
be identified and
eliminated by providing protective base material 72 (and optionally padding
84) to fill the gap
between certified surface 77 and customer 3D headform 66. While providing
protective base
material 72 within the gap between certified surface 77 and 3D headform 66 can
be thought of as
"filling" the gaps, in some embodiments, gaps will not physically exist
between a physically
constructed custom inner surface 82 and customer head 30. For example, an
analytical or
computational comparison can be made physically, graphically, analytically,
with CAD software, or
with other suitable program before forming custom inner surface 82 so that the
custom inner surface
can be formed, such as by being cut, from helmet base unit 86 to conform to
the length, width, and at
least one contour of the customer's head without an unwanted gap existing
between certified surface
77 and 3D headform 66 or customer head 30.
[0067] By forming custom inner surface 82 with additional base
material 72 between 3D
headform 66 and certified surface 77, custom-fitted helmet 81 may be more
comfortable than a
standardized or certified helmet that has base material 72 only extending to
certified surface 77.
Also, the custom-fitted helmet 81 will satisfy safety standard 71, or can be
effectively tested using
the same test line 73 for an entire class of custom-fitted helmets 81 instead
of requiring destructive
testing for each new custom-fitted helmet 81 that is made. Stated another way,
any custom-fitted
helmet 81 that includes a custom inner surface 82 that is outside or offset
from certified surface 77
by having a minimum distance between outer surface 83 and custom inner surface
82 that is greater
than a minimum distance between outer surface 83 and certified surface 77,
will also satisfy safety
standard 71 or can be effectively tested using the same test line 73. Stated
yet another way, any
custom-fitted helmet 81 that includes a custom inner surface 82 that does not
place customer head
30 or 3D headform 66 in such a way as to extend through or beyond certified
surface 77 toward
outer surface 83, will also satisfy safety standard 71, or can be effectively
tested using the same test
line 73.
1_0068] As such, in an embodiment, a person having ordinary skill in
the relevant art will
understand that certified surface 77 is a baseline surface indicating that any
other custom inner
surface 82 position outside ( or more distant from outer surface 83 that
certified surface 77)
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will produce helmets that meet the helmet safety standard, or can be
effectively tested using the
same test line 73. Accordingly, custom-fitted helmets 81 comprising custom
inner surfaces 82
can be certified by measuring against certified surface 77 and testing against
test line 73 without
each custom-fitted helmet needing to undergo destructive testing like a non-
custom fitted helmet
78, as described above. Therefore, use of test headform 74 for the creation of
a uniform test
standard such as test line 73 relative to a certified surface 77 for a range
or class of custom-fitted
helmets 81 can remove the economic burden produced by destructive testing of
each custom-
fitted helmet 81, making large scale production of safety certified custom-
fitted helmets
practical.
[00691 A.s a non-limiting example, A.pplicant has worked with
responsible parties at
the Snell foundation and established an acceptable working method for
consistently positioning
ISO headforms with respect to certified surfaces 77 and within custom-fitted
helmets 81, or
models of the same, in such a way that test lines 73 will be constant or fixed
with respect to
various custom-fitted helmets, thereby allowing a single test to certify the
safety of a number of
similar helmets all having different inner surfaces, without the waste of
destroying custom made
helmets. FIGs. 6D-6F, described in greater detail below, illustrate a non-
limiting example of
how Applicant has worked with the Snell Foundation to produce a procedure for
testing custom
-fitted helmets 81.
100701 FIG. 6D shows a medium ISO test headform 74a disposed within a
custom-
fitted helmet 81 that comprises a certified surface 77 for a medium sized head
or headform.
However, because customer heads have unique topographies including differing
lengths, widths,
and contours from each other, the generic shape and contour of test headform
74a is different
from custom inner surface 82. Custom inner surface 82 extends out from
certified surface 77, or
stated another way, includes an actual dimension DA greater than minimum
dimension Dm
associated with certified surface 77. As such, custom inner surface 82 is only
partially in contact
with headform 74a and is not properly situated within custom-fitted helmet 81
as headform 66 or
customer head 30 would be. FIG. 6D shows headform 74a includes basic plane 75a
that is
rotated with respect to nominal basic plane 75 that is offset from the top of
the helmet faceport
by the HPI. FIG. 6D also shows that a top crown portion of headform 74a is not
in contact, or
aligned, with a top crown portion of custom inner surface 82. Instead, the top
crown portion of
headform 74a is offset from, and has a gap with respect to, the top crown
portion of custom inner
-26-
surface 82. Both the rotation and the poor fit between headform 74a and custom
inner surface 82 can
provide problems for using the headform for testing.
[00711 Similarly, FIG. 6E shows an alternative configuration in which
custom inner
surface 82 provides a problem for using medium ISO test headform 74a for
testing. In FIG. 6E,
medium ISO test headform 74a is disposed within a custom-fitted helmet 81 that
comprises the
custom inner surface 82 shown in FIG. 6D. However, instead of having basic
plane 75a of headform
74a different from the nominal basic plane 75, FIG. 6E shows the basic plane
75a of headform 74a
aligned with the nominal basic plane and properly offset from upper faceport
edge 76 according to
the HPL However, because the generic shape and contour of test headform 74a is
different from
custom inner surface 82, headform 74a is shown extending beyond inner surface
82. Practically
speaking, by allowing headform 74a to extend beyond inner surface 82, the
model presents a
situation in which a customer head 30 would be occupying space occupied by
protective base
material 72. As such, the configuration shown in FIG. 6E is also impractical
for impact testing
custom-fitted helmet 81 because misalignments between medium headform 74a and
inner surface
82 of custom-fitted helmet 81 result from the unique length, width, and
contours of an actual
customer head 30 or headform 66 used for the formation of custom inner surface
82. Therefore, the
misalignments between medium headform 74a and inner surface 82 of custom-
fitted helmet 81
shown in FIGs. 6D and 6E suggest a medium ISO test headform 74a is too large
for at least some
custom-fitted helmets 81 comprising a certified surface 77 designed for medium
head sizes.
[0072] FIG. 6F shows an embodiment in which a smaller TSO headform
such as small
ISO test headform 74b, rather than a medium ISO test headform 74a, is disposed
within a custom-
fitted helmet 81 for the testing of the custom-fitted helmet comprising a
certified surface 77 for
a medium sized head or headform. By using small ISO test headform 74b,
headform 74b can fully
contact all portions of custom inner surface 82 and be properly situated
within custom= fitted
helmet 81 as headform 66 or customer head 30 would be. Additionally, by using
small ISO test
headform 74b the basic plane of headform 74b can also be aligned with the
nominal basic plane
and properly offset from upper faceport edge 76 according to the HP1. Thus,
the smaller volume of
headform 74b allows for more flexibility in fitting the headform within an
area of custom inner
surface 82 that is less than an area of certified surface 77. Additionally, in
order for small ISO
headform 74a to provide acceptable testing results for a medium sized
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certified surface, the small ISO headform 74a can be weighted to match, and to
respond during
testing, as medium sized ISO headform 74b.
[0073] The
exemplary embodiment of FIG. 6E shows test line 73b associated with
headform 74b and aligning on outer surface 83 of custom-fitted helmet 81 at a
position or
location different from test line 73. However, the presence of differently
positioned test lines
resulting from different ISO headforms can be ignored for the purposes of
establishing the
impact line so long as the ISO headform being used is properly aligned with
helmet and 81 and
within, or does not pass through) certified surface 77. Thus, the established
test line 73 is used
for impact testing while using the properly weighted small ISO headform 74b.
While test
headforms 74a and 74b have been referred to as medium and small sized
headforms respectively,
a person of ordinary skill of the art will understand that any first and
second headforms of
differing sizes could be used and be equally applicable to the foregoing
example.
[0074]
Furthermore, as has been discussed in relation to FIGs. 6B-6F, different ISO
headforms can be used for establishing a test line and for conducting impact
testing, which is in
contrast to conventional testing in which only a single ISO headform has been
used for both
establishing the test line and the conducting the impact testing. As discussed
above, a first ISO
headform, such as headform 74 shown in FIG. 6B, can be used for establishing
the location and
position of test line 73 with respect to certified surface 77. A second ISO
headfbrrn, such as
headform 74b shown in FIG. 6F, can be used for conducting the impact testing
of custom-fitted
helmet 81.
100751 After
determining what inner surface 82 of custom-fitted helmet 81 will be,
based for example on customer head data and helmet safety standard 71, inner
surface 82 can be
formed. As indicated above with reference to FIG. 4C, and shown in FIGs. 7A-
7B, a helmet
base unit 86 can be used to form custom-fitted helmet 81, including inner
surface 82, which is
customized to the topography or the length, width, and at least one contour of
customer head 30
Or 3D headform 66. Helmet base unit 86 can be made of impact protective
material that is easily
removable or cuttable to conform to customer head 30, headform 66, or both.
helmet base unit
86 can be formed of an energy attenuating material such as EPS, EPP, plastic,
foam, PET, VN,
PLT, EVA, cork, rubber, orbathane, Zorbium, EPLA, brook foam, or other
suitable material or
blended combination or hybrid of material.
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[00761 Helmet base unit 86 includes an outer surface 83, a custom inner
surface 82,
and protective base material 72 between the outer and inner surface that will
accommodate both
helmet safety standard 71 and 3D headform 66. Thus, helmet base unit 86 can be
of any size and
shape before being customized to fit customer head 30. Customization of base
unit 86 for the
formation of custom-fitted helmet 81 can be by an additive or subtractive
process. In fact,
helmet base unit helmet 86 may, in particular customizable embodiments, be
initially formed as a
block of protective material that is entirely trimmed down to form the
customized helmet shape
and design that conforms to customer head 30 according to 3D headform 66.
Thus, helmet base
unit 86 can be initially formed as a non-descript block base unit or as a
helmet-shaped base unit
that includes material inside and outside of the final customized helmet,
which will be
customized through removing excess material from the helmet base unit.
Alternatively, helmet
base unit 86 can be a helmet-shaped base unit that includes material inside
that will be
customized through removing excess material and an outer surface 83 that does
not require
customization. An example of a helmet base unit 86 that includes an outer
surface 83 that does
not require customization and a custom inner surface 82 that leaves material
inside the helmet
base unit that will be customized is illustrated in F]G. 7B. Additionally,
formation of custom-
fitted helmet 81 can be formed by an additive process, such as 3D printing, to
build-up outer
surface 83 and custom inner surface 82.
100771 However, in order to minimize an amount of protective base
material 72 that
can be removed to reduce OT minimize weight and size of custom-fitted helmet
81, helmet base
unit 86 can be formed such that outer surface 83 is formed with a shape, form,
and contour equal
to a final shape, form, and contour of the final custom-fitted helmet 81.
Similarly, helmet base
unit 86 can be formed such that custom inner surface 82 includes a shape,
form, and contour that
approximates or is somewhat larger than the final shape, form, and contour of
custom inner
surface 82 of completed custom-fitted helmet 81. Thus, by preparing a helmet
base unit 86 that
approximates a final shape and design of custom-fitted helmet 81, the amount
of protective base
material 72 that is removed for customizing custom inner surface 82 is
reduced.
[00781 in order to ensure that helmet base unit 86 approximates a final
shape and
design of custom-fitted helmet 81, for a plurality of customers of different
head shapes and sizes,
a number of helmet base unit models including sizes ranging from a small size
to a large size can
be provided. Thus, helmet base unit 86 can be selected from a number of helmet
base unit
-29-
models to have the smallest possible helmet size, thereby minimizing helmet
weight and size while
still allowing customer 20 to have a custom-fitted helmet 81 with a thickness
greater than or equal to
minimum dimension Dm of helmet safety standard 71 between a surface of
customer head 30 and
outer surface 83 of custom-fitted helmet 81. Dimensions of helmet base unit 86
can then be altered
to generate a computerized helmet model 88. Computerized helmet model 88
includes at least a
digital data set indicative of a portion of a helmet. In some embodiments,
computerized helmet
model 88 includes a model of at least custom inner surface 82 of custom-fitted
helmet 81.
Additionally, and as discussed more fully below, in some cases all of the
dimensions of the custom-
fitted helmet 81 may be calculated by a processor associated with the database
24. In a particular
embodiment, a graphical comparison can be made visually or analytically
between headform 66,
minimum dimensions DM of helmet safety standard 71, and helmet base unit 86 to
visually
determine if any minimum dimensions Dm are not met and extend into a space
occupied by headform
66 or extend beyond helmet base unit 86. If a portion of headform 66 does
extend into at least a
portion of minimum dimensions Dm for helmet base unit 86, a larger or
different helmet base unit
model is chosen.
[0079] As shown in FIG. 7C, after obtaining head data for customer
head 30 and
optionally generating 3D headform 66, the 3D headform or head data is compared
to helmet
safety standard 71 to form custom-fitted helmet 81 based on the 3D headform or
head data such
that the custom-fitted helmet satisfies the safety standard and custom inner
surface 82 comprises
a topography that conforms to the length, width, and at least one contour of
the customer head.
Forming of custom-fitted helmet 81 can be at a second location, different from
the first location
where the head data for customer head 30 is obtained. As indicated above,
custom-fitted helmet
81 can be formed by an additive or subtractive process. For subtractive
processes in which
material is removed to form custom inner surface 82, an appropriate helmet
base unit 86 is
determined, as described above, that will allow for the minimum dimensions Dm
required to
satisfy helmet safety standard 71, while minimizing or reducing additional
helmet thickness and
weight not required for comfort. In a particular, non-limiting embodiment,
helmet base unit 86
is selected to have a size from which about 6mm-8mm of material is removed to
form custom
inner surface 82 of custom-fitted helmet 81. Accordingly, a head cavity 90 of
helmet base unit
86 is approximately 20% smaller than head cavity 92 of custom-fitted helmet
81. Stated another
way, head cavity 90 of helmet base unit 86 includes a size or volume
Date Recue/Date Received 2020-08-31
approximately 81% of a size or volume of head cavity 92. However, various
other standard
initial thicknesses, volumes, and sizes may be used and could be more
practical depending upon a
number of factors, including a style of helmet, a type of impact protection
provided, a type of
material used, or a combination of factors.
[0080] Depending upon what type of material is used for protective
base material 72 of
helmet base unit 86, any of several different methods may be used to remove
excess protective base
material 72 from the helmet base unit. Those of ordinary skill in the art will
readily understand or
determine without undo experimentation which method of removing protective
base material 72 is
best based on a composition of the protective base material. FIG. 7C shows use
of a CNC machine
or routing machine 94 including cutting blade 96 is a method that works well
for removal of excess
protective base material 72 comprising FPS. To the contrary, use of a CNC
machine can be less
effective for EPP than with EPS because EPP tends to melt or deform during
removal of protective
base material 72 with CNC machine 94. Rotating cutting blade 96 is used to
carve away excess
protective base material 72 from helmet base unit 86 so that custom inner
surface 82 comprises a
topography that conforms to customer head 30, 3D headform 66, or both. An
appropriate jig 98
can be used to hold helmet base unit 86 during removal of a portion of
protective base material 72.
Jig 98 can include any structure configured to prevent undesired movement of
base unit 86 during
removal of protective base material 72. As shown in FIG. 7C, jig 98 can
comprise interlocking
members 100 that interface with jig 98 and are configured to interlock with
helmet base unit 86.
Helmet base unit 86 can include posts or protrusions 102 formed as part of the
helmet base unit and
configured to interlock with jig 98. Posts 102 can be of any shape and can be
built-up on helmet base
unit 86, or alternatively, can be formed as openings or holes that act as
receptors for receiving
interlocking members 100 of jig 98. When posts 102 are formed as protrusions
extending away from
outer surface 83, the posts may be removed or may be covered by other
coverings on the finished
custom-fitted helmet 81 after having been used to interlock with jig 98.
Alternatively, the jig may
be formed to interlock or interface with a permanent feature or shape on the
helmet base unit that is
not removed by subsequent processing.
[0081] Importantly, customization of custom inner surface 82 to
include a topography
that conforms to the length, width, and at least one contour of the customer
head 30 can be done with
any shape or style of helmet. Other non-limiting examples for other helmet
types are shown
31
Date Recue/Date Received 2020-08-31
in FIGs. 8A-9D. In particular embodiments, excess protective base material 72,
including posts
102, can be removed after helmet base unit 86 has been coated or inserted into
an outer shell such
as a decorative outer shell. Alternatively, excess protective base material
72, including posts 102,
can be removed before helmet base unit 86 has been coated or inserted into an
outer shell, or
removed without subsequent use of an outer shell.
[0082] FIG. 7D shows custom-fitted helmet 81 including a finished
custom inner
surface 82 comprising a topography that comprises a length, width, and at
least one contour of
customer head 30. Custom-fitted helmet 81 of FIG. 7D differs from helmet base
unit 86 shown in
FIG. 7A in that a thickness or an actual dimension DA between outer surface 72
and custom inner
surface 82 of custom-fitted helmet 81 in FIG. 7D is less than a thickness or
an actual dimension DA
between outer surface 83 and custom inner surface 82 of helmet base unit 86
shown in FIG. 7A.
Stated another way, the actual dimension DA between outer surface 83 and
custom inner surface 82
of helmet base unit 86 in FIG. 7A is greater than the thickness or actual
dimension DA between
outer surface 83 and custom inner surface 82 of custom-fitted helmet 81 in
FIG. 7D.
[0083] The process of forming a customized custom inner surface 82 for
custom- fitted
helmet 81 is applicable not only to a tangible helmet base unit 86, but is
likewise applicable to
computerized helmet models 88. In an embodiment, a computerized helmet model
88 can be a
virtual or graphical model that comprises dimensions, forms, shapes, contours,
and characteristics
of a final helmet that include an outer surface 83 and also satisfies helmet
safety standard 71. In
other words, computerized helmet model 88 can be a virtual representation of a
tangible or physical
helmet base unit 86. A portion of computerized helmet model 88 can be formed
or modified based
on bead data of customer head 30 or based on 3D headform 66. Specifically,
computerized helmet
model 88 can be formed or modified such that a custom inner surface 82
comprises a topography
that conforms to a length, width, and at least one contour of customer head
30, 3D headform 66, or
both. Computerized helmet model 88 can be used as a starting point for
customization of a
custom inner surface 82 by modifying helmet base unit 86 to form custom-fitted
helmet 81, as
indicated above with respect to FIGs. 7A-7D. Alternatively, computerized
helmet model 88 can be
used to form custom inner surface 82 by an additive process. Custom inner
surface 82 of custom-
fitted helmet 81 can be created, for example, using a 3D printer, a customer
head data-specific
mold, or other one-time or one-off manufacturing
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method, including, by way of example and not by limitation, physical casting
with plaster, Room
Temperature Vulcanizing (R'FV), or casting or molding with Urethane, Clay,
Wax, Paper Mache
or other materials used for casting, molding, or copy milling.
[0084] FIG. 8A shows a cross sectional view of custom-fitted helmet 81
formed as a
multi-layer helmet 106 that includes an outer layer or first layer 108 and an
inner layer or second
layer 110. Outer layer 108 includes outer surface 83 and inner layer 110
includes custom inner
surface 82. While multi-layer helmet 106 is shown with two distinct layers,
namely outer layer
108 and inner layer 110, any number of a layers can be used, including any
number of layers
disposed between the custom inner surface 82 and outer surface 83.
[00851 Inner layer 110 can be formed of a material that is identical,
similar, or
different from outer layer 108. Inner layer 110 can be coupled to outer layer
108 by chemical
bonds, mechanical bonds, or both, and can be coupled using an adhesive, a
bonding agent, or
friction. Outer layer 108 can be a standard helmet shell of impact protective
material similar to
helmet base unit 86 that includes a protective base material 72 and further
comprises an outer
surface 83. An inner surface of outer layer 108 is not configured to be in
contact with user head
30, but instead is configured to be in contact with, or coupled to, one or
more inner layers 110.
100861 Custom inner surface 82 of inner layer 110 can be formed by an
additive or
subtractive process. timer layer 110 can be applied as a separately
manufactured insert from
outer layer 108, in which inner layer 110 is formed by spraying or as another
molded material
added to outer layer 108 during manufacturing, or later, or in any other
manner known in the art.
Portions of one or more inner layers 110 can be sculpted or otherwise removed
as part of a
subtractive process such that custom inner surface 82 conforms to head data
for customer head
30 or 3D headform 66. A final custom inner surface 82 can be formed either
before inner layer
110 is added to outer layer 108, or after inner layer 110 is added to outer
layer 108. Inner layer
110 includes custom inner surface 82 that comprises a topography that conforms
to the length,
width, and at least one contour of customer head 30. Custom inner surface 82
can be in direct
contact with customer head 30 or customer hair 32. Alternatively, custom inner
surface 82 can
be coupled or in contact with one or more padding or interface layers 84 that
are in direct contact
with customer head 30 or customer hair 32. Padding layer 84 can be disposed
over custom inner
surface 82 of custom-fitted helmet 81, as a layer comprising a uniform
thickness. Alternatively,
padding layer 84 can be formed as a layer comprising a variable or differing
thickness in which
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various portions of the padded layer can be formed with different amounts of
padding or
cushioning relative to specific portions of customer head 30 or custom-fitted
helmet 81.
However, when padding layer 84 is formed with variable thickness the different
amounts of
padding need not be used to account for differences between a topography of an
inner surface of
a generic helmet and a topography of the customer's head as has been
conventionally done with
generic one-size-fits-many helmets.
[0087] in particular embodiments, inner layer 110 can be formed of a
material that is
more easily removable or cuttable than outer layer 108. Depending upon the
manufacturing
processes used for forming custom inner surface 82, inner layer 110 can be
formed of any
suitable protective helmet material known in the art, including EPS, various
foams, EPP, Plastic,
expanded polyethylene, VN, PU, EVA, Cork, Rubber, Sorbathane, Zorbium, EPLA,
brock foam.,
or combinations of any of the above.
[0088] For subtractive methods of forming custom inner surface 82 of
inner layer
110, any of several different methods may be used to remove excess material
from the inner
layer depending upon the protective material used in forming helmet base unit
86. Those of
ordinary skill in the art will readily understand or determine without undo
experimentation based
on the protective material used in helmet base unit 86, which method of
removal is best for
protective base material 72. One method that works well with removal of excess
EPS is routing
or CNC machining, as described above with respect to FIG. 7C. By forming multi-
layer helmet
106 with outer layer 108 of impact protective material, and disposing inner
layer 110 adjacent to
the inner layer, a better fitting and better performing helmet can be achieved
that is unique to
each customer 20.
100891 In an embodiment, as indicated above, an additional inner layer
can be applied
as an insert that is separately manufactured from an outer layer. The inner
layer can, for
example, be formed by spraying, or by any other manner known in the art. The
inner layer insert
includes inner layer 110, as shown and described with respect to FIG. 8A.
Additionally,
inclusion of an inner layer as part of a method for providing a custom-fitted
helmet can be
applicable to all helmet types, including full face helmets for various
sports, as mentioned above,
including motorsports and powersports, as is also indicated below, for
example, with respect to
FIGs. 9A and 9B. As a non-limiting example, a custom-fitted in-molded
polycarbonate
(PC)/EPS liner can be inserted into a stock helmet to replace an existing
stock helmet liner or
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stock comfort padding layer. In such a case, a manufacturer, technician, or
even customer 20
removes the existing comfort padding or liner from the stock helmet and places
the custom
manufactured insert (such as the custom-fitted in-molded PC/EPS liner) into
the stock helmet.
However, as customers are not typically experts of fitting helmets, in some
embodiments, fitting
by a manufacturer or trained technician is preferable. The custom manufactured
insert is
installed within the stock helmet to provide a customized version of the stock
helmet. The
custom manufactured insert can be installed into the stock helmet using
existing mechanical
fasters. For example, the custom manufactured insert can be installed in the
stock helmet using
the same padding snaps that were used to couple the stock comfort padding or
liner to an outer
layer of the stock helmet. Advantageously, the custom. manufactured insert can
further comprise
comfort padding, which can be thinner than the existing comfort padding.
[0090] FIG. 8B shows a perspective view of multi-layer helmet 106. While
multi-
layer helmet 106 can be fonned as any type of helmet, FIGs. 8A and 8B show a
particular non-
limiting embodiment for a bicycle helmet. For any of the embodiments disclosed
or
contemplated herein, additional customizing may be done to custom-fitted
helmet 81, including
forming a customized helmet protective material 112 as part of the custom-
fitted helmet. For
example, FIG. 8B shows protective material 112 fonned as a protective,
functional, or decorative
outer shell funned over outer surface 83 of outer layer .108. Additional
customization can further
include padding layer 84 added to custom inner surface 82, straps including
chin straps and neck
straps coupled to custom-fitted helmet 81, as well as colors and stylistic
features. Thus, those of
ordinary skill in the art will readily understand from this disclosure that
multiple levels of
customization are now possible and practical in a business environment for the
customization of
custom-fitted helmets 81.
[00911 FIG. 9A shows another embodiment of a custom-fitted helmet 81, in
which an
inner layer 114 comprising additional material can be added to outer layer
108, as described
above with respect to FIGs. 8A and 813. Inner layer 114 differs from inner
layer 110 in that
instead of being a being composed of a single monolithic piece like inner
layer 110, inner layer
114 comprises a plurality of segments 116. Segments 116 can be a flexible,
semi-flexible,
extendable, or reconfigurable component that are permanently joined,
temporarily joined, or
separate from one another and separately attached to outer layer 108. Thus,
segments 116 are
formed in one or more contiguous or disjointed parts and assembled as one
piece or as separate
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pieces to outer layer 108. FIG. 9A shows a gap or channel 118 is formed or
exists between
segments 116, such that the segments are not directly connected or do not
directly contact one
another.
[0092] FIG. 9B shows another embodiment in which segments 116 are
outside of
outer layer 108 and are connected by joining members 120. Joining member 120
can be formed
of aluminum, nylon, plastic, or other flexible material, and extend between
segments 116 to
provide a fixed or variable spacing, such as a gap or channel, between the
segments. Joining
members 120 can be partially exposed from segments 116 and partially embedded
within the
segments. Single or individual joining member can be coupled to, or extend
through, multiple
segments 116. In an embodiment, a plurality of segments 116, including a
totality of segments
116, is connected with a single joining member 120 that includes separate
spoke portions
extending radially from a central area.
[00931 As illustrated in both FIGs. 9.A and 9B, segments 11.6 can be
manufactured
outside of outer layer 108 and then assembled into a custom-fitted helmet 81,
such as by being
coupled to outer layer 108. Accordingly, segments 116 can be arranged to form
inner layer 114
that comprises custom inner surface 82 and further comprises a topography that
conforms to the
length, width, and at least one contour of customer head 30 or headform 66.
[00941 FIG. 9B further shows segments 116 of inner layer 110 can be
arranged or
formed in a flat or planar array or a substantially flat or planar array with
a number of segments
116 disposed around a central or crown segment 117 and attached by joining
members 120.
Similarly, segments 116 may also be formed in an array that is not completely
flat or planar, but
is sufficiently flat or planar to allow cutting blade 96 of CNC machine 94 or
other sculpting tool
to access portions of segments 116 necessary for forming custom inner surface
82.
Advantageously, cutting blade 96 of CNC machine 94, or other sculpting tool,
can be used to
form, sculpt, or pattern custom inner surface 82 of segments 116 that would be
inaccessible if not
in a flattened form. For example, while segments 116 are disposed in the flat
arrangement,
removal of material from segments 116 in hard to reach places, such as at a
portion of a hehnet
following a contour of a customer's occipital curve, arc made accessible to
traditional CNC or
sculpting machines. Traditional CNC machines cannot create a helmet recurve to
match a
customer's occipital curve on a rigid helmet base unit because the cutting
portion of the CNC
machine cannot change an angle of the cutting blade from a strict vertical
position to a required
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agled position. By placing segments 116 in a substantially flat or planar
position, a topography of
custom inner surface 82 can he formed to match contours of customer head 30
with only vertical
access to segments 116. Thus, a custom-fitted helmet 81 can include a recurve
formed of a rigid
impact protective material such as EPS or EPP or of a semi-rigid impact
protective material such as
vinyl nitrile (VN), VN foam, or other suitable foam or similar material. After
completion of custom
inner surface 82 by removal of material by a CNC machine comprising a vertical
blade, the flat or
substantially flat array of segments 116 can then be formed as part of a
custom-fitted helmet 81, such
as by being inserted into, and coupled to, outer layer 108.
[0095] FIGs. 10A and 10B show additional exemplary embodiments of
custom-fitted
helmets 81, in which portions of the helmets other than just atop inner
portion near a crown of user
head 30 is customized. For example, by gathering data relating to placement
and shape of one or
more of a brow, nose, ears, eyes, mouth, cheek, chin, or neck of customer 20,
and by knowing how
the particular helmet will be used, other customizations may be made. For
example, other helmet
components that may contact the face or head 30 of customer 20 can be adjusted
to comprise a
surface or topography that matches a shape, size, or contour, of any feature
of customer 20.
Additionally, a customer's FOV can be increased by optimizing a position of
the customer's eyes
relative to a faceport opening or eye openings within the helmet
[0096] Specifically, FIG. 10A shows custom-fitted football helmet 124,
and FIG. 10B
shows custom-fitted motorcycle helmet 128. Because custom-fitted football
helmet 124 and
custom-fitted motorcycle helmet 128 include helmet portions, such as the side
panels or face guard
area that surround sides of the face, cheeks, or both of customer 20, portions
of helmets 124 and 128,
such as custom panels, can be formed to conform to the face, cheeks, or both
of customer 20 for a
more comfortable, better fitting helmet. In biking, for example, helmets are
worn differently if the
biker is touring, staged, or racing position. For bike racing, the helmet can
be adapted and
conformed to allow the customer to be in a stage or race position without the
helmet interfering with
the customer's sight based on the particular customer's eye position.
Relatedly, a customized neck
component for a hockey helmet comprising an inner surface shaped to conform to
the customer's
neck can also be formed.
1_0097 J It is to be understood that the disclosure is not limited to
the exact details of
construction, operation, exact materials, or embodiments shown and described,
as obvious
modifications and equivalents will be apparent to one skilled in the art; for
example, the
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photographs may be digital photographs or paper based photographs that may
then be scanned
into digital form. While the specific embodiments have been illustrated and
described, numerous
modifications come to mind without significantly departing from the spirit of
the disclosure.
[0098] As used herein, the terms "component," "system" and the like in
relation to
discussions about computer-related processes and systems are intended to refer
to a computer-
related entity, either hardware, a combination of hardware and software,
software, or software in
execution. For example, a component may be, but is not limited to being, a
process running on a
processor, a processor, an object, an instance, an executable, a thread of
execution, a program, a
computer, or both. By way of illustration, both an application running on a
computer and the
computer can. be a component. One or more components may reside within a
process, a thread of
execution, or both, and a component may be localized on one computer and/or
distributed
between two or more computers.
[0099] Furthermore, all or portions of the computer-related processes
and systems
can be implemented as a method, apparatus or article of manufacture using
standard
programming and/or engineering techniques to produce software, firmware,
hardware, or any
combination thereof to control a computer to implement the disclosed
innovation. The term
"article of manufacture" as used herein is intended to encompass a computer
program accessible
from any computer-readable device or media. For example, computer readable
media can
include but are not limited to magnetic storage devices (e.g., hard disk,
floppy disk, magnetic
strips. . . ), optical disks (e.g., compact disk (CD), digital versatile disk
(DVD) . ), smart
cards, and flash memory devices (e.g., card, stick, key drive . . . ).
Additionally, it should be
appreciated that a carrier wave can be employed to carry computer-readable
electronic data such
as those used in transmitting and receiving electronic mail or in accessing a
network such as the
Internet or a local area network (LAN). Of course, those skilled in the art
will recognize many
modifications may be made to this configuration without departing from the
scope or spirit of the
claimed subject matter.
[001001 Where the above examples, embodiments and implementations reference
examples, it should be understood by those of ordinary skill in the art that
other helmet and
manufacturing devices and examples could be intermixed or substituted with
those provided. In
places where the description above refers to particular embodiments of helmets
and
customization methods, it should be readily apparent that a number of
modifications may be
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made without departing from the spirit thereof and that these embodiments and
implementations
may be applied to other to helmet customization technologies as well.
Accordingly, the
disclosed subject matter is intended to embrace all such alterations,
modifications and variations
that fall within the spirit and scope of the disclosure and the knowledge of
one of ordinary skill
in the art.
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