Note: Descriptions are shown in the official language in which they were submitted.
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HELMET PADDING SYSTEM
CROSS REFERENCE TO RELATED APPLICATION
This application is related to and claims the benefit of U.S. Application No.
14/729,266, entitled HELMET PADDING SYSTEM, filed on June 3, 2015, the
contents of
which are incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates generally to the field of protective headgear, and
more particularly, to impact-resistant padding for protective headgear.
BACKGROUND OF THE INVENTION
Conventionally, participants in "contact" sports (e.g., wrestling, football,
rugby) wear protective headgear to cushion the force of impacts that are
regularly
received during those events. In recent years, the negative health effects of
the
impacts to the head experienced during such contact sports have been a matter
of
focus. These negative health effects can be diminished or minimized by
effectively
cushioning participants from the forces of impacts. Accordingly, improved
structures,
such as impact-resistant headgear, are desired to lessen the impact forces
experienced
by those participants.
SUMMARY OF THE INVENTION
Aspects of the present invention are directed to helmet padding systems.
In accordance with one aspect of the present invention, a helmet padding
system is disclosed. The helmet padding system includes a rigid shell and a
spacing
pad. The rigid shell is configured to cover a top of a user's head and be worn
under a
baseball cap. The rigid shell includes an opening formed in an area of the
rigid shell
opposite the front of the user's head when the rigid shell is worn on the
user's head.
The spacing pad is positioned within the rigid shell. The spacing pad includes
a layer of
elastomeric material.
In accordance with another aspect of the present invention, another
helmet padding system is disclosed. The helmet padding system includes a cap,
a rigid
shell, and a spacing pad. The cap has a cut-out in a rear portion thereof. The
rigid
shell is configured to be worn under the cap. The rigid shell comprises an
opening
formed in an area of the rigid shell directly beneath the cut-out in the cap
when the
rigid shell is worn under the cap. The spacing pad is positioned within the
rigid shell.
The spacing pad includes a layer of elastomeric material.
In accordance with yet another aspect of the present invention, another
helmet padding system is disclosed. The helmet padding system includes a rigid
shell,
a facemask, and a spacing pad. The rigid shell includes a body portion and a
pair of
side portions. The body portion is Configured to cover a top of a user's head
and be
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worn under a baseball cap. The body portion has a lower front edge between the
pair
of side portions. The pair of side portions extend downward below the lower
front edge
of the body portion. The facemask is coupled to the rigid shell, and is
configured to
cover the user's face when the rigid shell is worn by the user. The spacing
pad is
positioned within the rigid shell, and includes a layer of elastomeric
material.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is best understood from the following detailed description
when read in connection with the accompanying drawings, with like elements
having
the same reference numerals. When a plurality of similar elements are present,
a
io single reference numeral may be assigned to the plurality of similar
elements with a
small letter designation referring to specific elements. When referring to the
elements
collectively or to a non-specific one or more of the elements, the small
letter
designation may be dropped. According to common practice, the various features
of
the drawings are not drawn to scale unless otherwise indicated. To the
contrary, the
dimensions of the various features may be =expanded or reduced for clarity.
Included in
the drawings are the following figures:
FIG. 1 is an image illustrating an exemplary helmet padding system in
accordance with aspects of the present invention;
FIG. 2 is an image illustrating an exemplary helmet shell of the helmet
padding system of FIG. 1;
FIG. 3 is an image illustrating exemplary absorption pads of the helmet
padding system of FIG. 1;
FIG. 4 is an image illustrating an exemplary spacing pad of the helmet
padding system of FIG. 1;
FIG. 5 is an image of the exemplary spacing pad of FIG. 4 in a helmet
shell;
FIG. 6 is an image illustrating another exemplary spacing pad of the
helmet padding system of FIG. 1;
FIG. 7 is an image of the exemplary spacing pad of FIG. 6 in a helmet
shell;
FIG. 8 is an image illustrating yet another exemplary spacing pad of the
helmet padding system of FIG. 1;
FIGS. 9A-9D are images illustrating an exemplary impact-resistant pad in
accordance with aspects of the present invention;
FIG. 10A-10C are images illustrating an exemplary protective headgear
system in accordance with aspects of the present invention;
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FIG. 11 is an image illustrating another exemplary protective headgear
system in accordance with aspects of the present invention;
FIG. 12 is a cross-sectional diagram illustrating another exemplary
helmet padding system in accordance with aspects of the present invention;
FIG. 13 is an image illustrating another exemplary spacing pad of the
helmet padding system of FIG. 1;
FIGS. 14A-14D are images illustrating another exemplary helmet
padding system in accordance with aspects of the present invention;
FIGS. 15A-15C are images illustrating an alternative embodiment of the
io exemplary helmet padding system of FIGS. 14A-14D;
FIGS. 16-18 are images illustrating embodiments of another exemplary
helmet padding system in accordance with aspects of the present invention;
FIGS. 19A and 19B are images illustrating another exemplary helmet
padding system in accordance with aspects of the present invention;
FIGS. 19C and 19D are images illustrating a cross-sectional view of the
exemplary helmet padding system of FIGS. 19A and 19B;
FIGS. 20A and 20B are images illustrating an alternative embodiment of
the helmet padding system of FIGS. 19A and 19B;
FIG. 21 is another image illustrating the embodiment of FIGS. 20A and
20B within a conventional cap; and
FIGS. 22 and 23 are images illustrating another exemplary helmet
padding systems in accordance with aspects of the present invention;
FIGS. 24A-24C are images illustrating another exemplary helmet padding
system in accordance with aspects of the present invention;
FIG. 25 is an image illustrating an exploded embodiment of the helmet
padding system of FIGS. 24A-24C;
FIG. 26 is an image illustrating an alternative embodiment of a cutout of
the helmet padding system of FIGS. 24A-24C;
FIG. 27 is an image showing an interior of the helmet padding system of
FIGS. 24A-24C;
FIGS. 28A and 28B are images illustrating alternative embodiments of
the helmet padding system of FIGS. 24A-24C;
FIG. 29 is an image illustrating the helmet padding system of FIGS. 24A-
24C worn beneath a baseball cap;
FIGS. 30A and 30B are images illustrating an alternative embodiment of
the helmet padding system of FIGS. 20A and 20B;
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FIGS. 31A-31C are images illustrating the helmet padding system of
FIGS. 30A and 30B with a removable plate; and
FIGS. 32A and 32B are images illustrating an alternative embodiment of
the helmet padding system of FIGS. 24A-24C.
DETAILED DESCRIPTION OF THE INVENTION
The embodiments of the invention described herein relate to helmet
padding and protective headgear systems that incorporate impact-resistant pads
beneath a user's helmet to cushion impacts on the helmet from the user's head.
As
used herein, the term "helmet" is not intended to be limited, but is meant to
io encompass any headgear worn for protection during an activity in which
an impact to
the head may occur. Additionally, as used herein, the term "impact-resistant"
is
intended to encompass any object that partially or fully lessens, diminishes,
dissipates,
deflects, or absorbs the mechanical force of an impact.
The exemplary systems and apparatus disclosed herein are configured to
lessen the force of an impact on the user's head. This makes them particularly
suitable
for use by participants in athletic activities, and particularly suitable for
participants in
traditional "contact" sports, such as wrestling, American football, or rugby,
where high-
force impacts may be commonly experienced. While the exemplary embodiments of
the invention are described herein with respect to athletic activities, it
will be
understood that the invention is not so limited. Suitable applications for the
systems
and apparatus of the present invention include, for example, military helmets
or
construction helmets. Other suitable applications will be readily understood
by one of
ordinary skill in the art from the description herein.
Referring now to the drawings, FIG. 1 illustrates an exemplary helmet
padding system 100 in accordance with aspects of the present invention. Helmet
padding system 100 may be worn by a user during an athletic activity. As a
general
overview, system 100 includes a helmet shell 110, a spacing pad 130, and a
plurality of
absorption pads 150. Additional details of system 100 are described herein.
Helmet shell 110 is configured to be positioned on a user's head. As
shown in FIGS. 1 and 2, helmet shell 110 completely encloses the upper portion
of the
user's head. This may be desirable in order to ensure any impacts to the
user's head
are absorbed by helmet padding system 100. Helmet shell 110 may include one or
more straps 112 for securing helmet shell 110 to the user's head. The size of
helmet
shell 110 is selected such that helmet shell 110 can accommodate the remaining
components of system 100 while still being securely positioned on the user's
head.
Where helmet shell 110 is a conventional helmet shell, it will be understood
that helmet
shell 110 may include its own integral, connected foam pads in addition to the
pads
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described with respect to system 100. It will be understood that the pads
described
with respect to system 100 may be pads provided in addition to the pads
provided in
conventional helmet shells 110. Suitable helmet shells 110 for use with the
present
invention will be known to one of ordinary skill in the art from the
description herein.
5 Spacing pad 130 is positioned within the interior of helmet shell
110. As
shown in FIGS. 4-8, spacing pad 130 comprises a central portion 132 and a
plurality of
extending portions 134 projecting outward from the central portion. Spacing
pad 130
may or may not be coupled to the interior of helmet shell 110. When spacing
pad 130
is coupled to helmet shell 110, central portion 132 is coupled to a central
region of the
interior of helmet shell 110, such that extending portions 134 project toward
the
peripheral edges of helmet shell 110.
Spacing pad 130 is formed from impact-resistant materials. For
example, spacing pad 130 may include a layer of elastomeric material. The
elastomeric
material may provide impact-resistance by absorbing and dissipating the force
of
impacts laterally along the surface of the elastomeric material. In one
exemplary
embodiment, spacing pad 130 consists of only a single layer of elastomeric
material.
In another exemplary embodiment, spacing pad 130 comprises two or more layers
of
elastomeric material. Spacing pad 130 may include the layers of elastomeric
material
directly adjacent each other, or in a more preferred embodiment, may include a
layer of
high tensile strength fibrous material between the layers of elastomeric
material.
Suitable materials for forming the elastomeric layer(s) include, but are
not limited to, urethane rubbers, silicone rubbers, nitrile rubbers, butyl
rubbers, acrylic
rubbers, natural rubbers, styrene-butadiene rubbers, and the like. In general,
any
suitable elastomer material can be used to form the above-described
elastomeric layers
without departing from the scope of the present invention. Suitable materials
for
forming the layer of high tensile strength fibrous material include, but are
not limited
to, aramid fibers, fiberglass, or other high tensile strength fibers. The
fibers may be
woven to form a cloth layer that is disposed between and generally separates
the
opposing elastomeric layers. The high tensile strength fibrous material layer
may
desirably block and redirect impact energy that passes through one of the
elastomeric
layers. Additional description of materials for forming spacing pad 130 may be
found in
co-pending U.S. Patent Application No. 13/331,004, the contents of which are
incorporated herein by reference in their entirety.
As shown in FIG. 4, spacing pad 130 may comprise an array of raised
portions 131 formed on a surface thereof. Raised portions 131 may have a
rectangular
shape, as shown in FIG. 4. However, one of ordinary skill in the art will
understand
that other shapes may be chosen. For example, raised portions 131 may have a
square
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shape or a diamond shape. Raised portions 130 desirably enable air circulation
across
spacing pad 130 and concentrate the load from an impact on spacing pad 130. An
array of raised portions 131. having a diamond shape may be particular
desirable, as
these raised portions 131 may enable greater flexibility of spacing pad 130.
As set forth above, spacing pad 130 may or may not be coupled to the
interior helmet shell 110. When spacing pad 130 is coupled to the interior of
helmet
shell 110, such coupling may be effected, for example, using adhesive. It may
be
desirable that the surface of spacing pad 130, including the entire lengths of
extending
portions 134, be adhered to the interior of helmet shell 110. The lengths of
extending
portions 134 may be limited, to prevent separation of extending portions 134
from
helmet shell 11.0 during an impact that deforms helmet shell 110.
Absorption pads 150 may be coupled to spacing pad 130. As shown in
FIG. 3, the plurality of absorption pads 150 includes a first large absorption
pad 152
and a number of remaining absorption pads 154. As shown in FIG. 1, absorption
pad
152 is configured to be coupled to the central portion of spacing pad 130, and
absorption pads 154 are configured to be coupled to the ends of the extending
portions
of spacing pad 130.
Absorption pads 150 are desirably shaped such that they do not directly
contact helmet shell 110 when spacing pad 130 is coupled to helmet shell 110.
Absorption pads 150 may be insulated from helmet shell 110 by the ends of
spacing
pad 130, and/or may be formed with a preferential curve, in order to create a
gap
between the outer surfaces of pads 150 and the interior of helmet shell 110.
Suitable
materials for use in forming absorption pads 150 include, for example,
conventional
closed or open-cell foams, elastomeric and/or polymer materials. Other
materials will
be known to one of ordinary skill in the art from the description herein.
FIGS. 4-8 and 13 show different embodiments of spacing pads 130a,
130b, 130c, 130d for use with the present invention. Each spacing pad 130a,
130b,
130c, 130d includes a respective central portion 132a, 132b, 132c, 132d and a
respective plurality of extending portions 134a, 134b, 134c, 134d. Features of
these
extending portions 134 will be described herein. It will be understood by one
of
ordinary skill in the art that any of the features described herein with
respect to one
embodiment of spacing pad 130 may be provided in any of the other embodiments.
As shown in FIGS. 4-8, extending portions 134 project outward at regular
intervals from their respective central portions 132. As shown in FIGS. 4 and
6, the
regular intervals may be approximately every 45 . As shown in FIG. 8, the
regular
intervals may be approximately every 900.
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As shown in FIGS. 6 and 7, extending portions 134b of spacing pad 130b
have end portions 136b. End portions 136b have a width greater than the width
of the
remainder of the respective extending portion 134b. The wider end portions
136b of
spacing pad 130b may be desirable in order to provide a large base for
absorption pads
150. The wide end portions 136b may be made sufficiently wide that the end
portions
136b of adjacent extending portions 134b overlap with each other when spacing
pad
130b is positioned within the helmet shell.
Additionally, as shown in FIGS. 6 and 7, spacing pad 130b may be
contained in a liner 137. Liner 137 may be configured to surround spacing pad
130b in
io order to provide a comfortable contact between the user and spacing pad
130b.
As shown in FIG. 8, extending portions 134c may be arranged axially
symmetrically relative to central portion 132c. Alternatively, as shown in
FIG. 4,
extending portions 134a may be arranged axially asymmetrically. Additionally,
as
shown in FIG. 4, extending portions 134a may have varying lengths projecting
from
central portion 132a.
The shapes and sizes of extending portions 134a, 134b, 134c may also
be dependent on the configuration of helmet shell 110, as set forth below.
As shown in FIGS. 5 and 7, the varying lengths of extending portions 134
may be selected to correspond to a peripheral contour of helmet shell 110. In
other
zo words, if the periphery of the helmet shell 110 has a varying contour,
the lengths of
extending portions 134 may be selected such that, when spacing pad 130 is
coupled to
helmet shell 110, the end of each extending portion 134 projects to within a
specified
distance of the periphery of helmet shell 110. In an exemplary embodiment,
extending
portions 134 project to within 0.125-2.0 inches of the periphery of helmet
shell 110.
Helmet shell 110 may include features that would interfere with the path
of extending portions 134. Accordingly, as shown in FIGS. 6 and 7, extending
portions
134b may be shaped to avoid interfering features in helmet shell 110, i.e., by
changing
direction. As shown in FIG. 6, at least one of the extending portions 134b may
have a
first portion 138 extending in a first direction and a second portion 139
extending from
the first portion 138 in a second direction different from the first
direction. This may
desirably ensure that the entire length of extending portion 134b is adhered
to the
interior of helmet shell 110.
Additionally, as shown in FIG. 13, a spacing pad 130d may be intended
for use in a baseball cap having a rear cut-out (e.g., for access to an
adjustable strap).
In this embodiment, one of extending portions 134d may be shortened and have a
rounded edge relative to the other extending portions. This extending portion
may be
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positioned to extend toward the rear cut-out of the baseball cap. This feature
may
desirably enable all of spacing pad 130d to fit comfortably within the
baseball cap.
The width and number of extending portions 134 may be selected based
on the circumference and size of helmet shell 110. As shown in FIGS. 4 and 6,
spacing
pad 130 may include a relatively large number of thin extending portions 134.
Alternatively, as shown in FIG. 8, spacing pad 130 may include a relatively
small
number of thick extending portions 134. In an exemplary embodiment, extending
portions 134 have a width of approximately 1" to approximately 4".
It will be understood that the number, shape, and size of extending
portions 134 in FIGS. 4-8 is shown merely for the purposes of illustration,
and is not
intended to be limiting. Spacing pads 130 having different numbers of
extending
portions 134 or differently shaped and sized extending portions 134 may be
used
without departing from the scope of the present invention, as would be
understood by
one of ordinary skill in the art from the description herein.
FIGS. 9A-9D illustrate an exemplary impact-resistant pad 200 in
accordance with aspects of the present invention. Impact-resistant pad 200 may
be
worn by a user as part of a protective headgear system during an athletic
activity, such
as a wrestling match. As a general overview, impact-resistant pad 200 includes
a top
portion 220 and side portions 240 and 250. Additional details of impact-
resistant pad
200 are described herein.
Top portion 220 is configured to be positioned covering a top of the
user's head. As shown in FIGS. 9A-9D top portion 220 may be approximately
circular,
and is sized to cover substantially the entire top of the user's head. In an
exemplary
embodiment, top portion 220 includes a plurality of openings 222. Openings 222
desirably provide ventilation to the user's head during use of impact-
resistant pad 200.
As shown in FIG. 9D, openings 222 are formed around the periphery of top
portion 220.
Side portions 240 and 250 extend downward from top portion 220. As
used herein, the term "side portion" is not intended to mean that portions 240
and 250
are on the "side" of the user's head (as opposed to the front or back). To the
contrary,
portions 240 and 250 may be located on any side of the user's head. As shown
in
FIGS. 9B and 9C side portions 240 and 250 cover a front portion and a back
portion of
the user's head, respectively. As further illustrated in FIG. 9A, back portion
250
extends a greater distance from top portion 220 than front portion 240. This
may be
desirable in order to provide greater protection to the back of the user's
head, and to
prevent obstructing the user's view.
Side portions 240 and 250 are not directly connected to each other, as
shown in FIG. 9A. In particular, a circumferential gap 260 is formed between
side
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portions 240 and 250. This may be particularly desirable so that impact-
resistant pad
200 may be worn by users of different head sizes. For example, when a user has
a
relatively small head, the gap 260 will be relatively narrow, and side
portions 240 and
250 will sit close to each other (or possibly in contact with each other) when
placed on
the user's head. However, when a user has a relatively large head, the gap 260
will be
relatively large, and side portions 240 and 250 will sit far from each other
when placed
on the user's head.
It will be understood that the number, shape, and size of side portions
240 and 250 in FIGS. 9A-9D is shown merely for the purposes of illustration,
and is not
intended to be limiting. Side portions 240 and 250 in different numbers or
having
different shapes or sizes may be used without departing from the scope of the
present
invention, as would be understood by one of ordinary skill in the art from the
description herein. Impact-resistant pad 200 is formed from substantially the
same
materials described above with respect to spacing pad 130.
Impact-resistant pad 200 is unconnected to any supporting structure. As
will be discussed in further detail herein, impact-resistant pad 200 is
configured to be
worn under a helmet. To this end, impact-resistant pad 200 is desirably thin.
In an
exemplary embodiment, impact-resistant pad 200 has a thickness of no greater
than
approximately 23 mm, and even more preferably, a thickness of no greater than
approximately 3 mm. The thickness of impact-resistant pad 200 may be selected
based on a number of factors, including for example the type of helmet, the
desired
level of impact protection, and the type of material encasing the pad (such as
moisture-
wicking, moisture-absorbent, cloth, or neoprene).
FIGS. 10A-10C illustrate an exemplary protective headgear system 300
in accordance with aspects of the present invention. Protective headgear
system 300
may be worn by a user during an athletic activity, such as a wrestling match.
As a
general overview, protective headgear system 300 includes an impact-resistant
pad
320 and a helmet 340. Additional details of protective headgear system 300 are
described herein.
Impact-resistant pad 320 is formed from materials designed to dissipate
the force of impacts on the user's head. In an exemplary embodiment, impact-
resistant pad 320 is an impact-resistant pad substantially as described above
with
respect to impact-resistant pad 200. In particular, impact-resistant pad 320
includes a
top portion 322 configured to be positioned covering a top of the user's head,
and side
portions 324 and 325 extending downward from top portion 322. Side portions
324
and 325 are not directly connected to each other, and define a circumferential
gap (not
shown) therebetween.
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Helmet 340 is configured to be positioned on a user's head overtop of
impact-resistant pad 320. Helmet 340 is unconnected to impact-resistant pad
320.
When helmet 340 is positioned overtop of impact-resistant pad 320, helmet 340
covers
the circumferential portions of impact-resistant pad 320. In an exemplary
5 embodiment, helmet 340 comprises conventional wrestling headgear, as
shown in
FIGS. 10A-10C. Helmet 340 includes a plurality of straps 342 for securing
helmet 340
to the user's head. Straps 342 extend over top portion 322 of impact-resistant
pad
320. Impact-resistant pad 320 may include guide portions (not shown) for
receiving
and properly positioning straps 342 of helmet 340.
10 It will be understood by one of ordinary skill in the art that
helmet 340 is
not limited to the embodiment shown in FIGS. 10A-10C FIG. 11 illustrates
another
exemplary protective headgear system 400 in accordance with aspects of the
present
invention. As a general overview, protective headgear system 400 includes an
impact-
resistant pad 420 and a helmet shell 440, as shown in FIG. 11. Helmet shell
440 is
configured to completely cover the user's head. This may be desirable in order
to
provide an additional layer of impact-resistance on top of impact-resistant
pad 420.
The size of helmet shell 440 is selected such that helmet 440 can accommodate
impact-resistant pad 420 therein while still being securely positioned on the
user's
head. In an exemplary embodiment, helmet shell 440 is a helmet shell
substantially as
described with respect to helmet shell 110. Suitable helmet shells 440 for use
with the
present invention will be known to one of ordinary skill in the art from the
description
he
FIG. 12 illustrates an exemplary helmet padding system 500 in
accordance with aspects of the present invention. FIG. 12 shows an exploded
cross-
sectional diagram of helmet padding system 500 through a central portion
thereof.
Helmet padding system 500 may also be worn by a user during an athletic
activity. As
a general overview, system 500 includes a helmet shell 510, a spacing pad 530,
and a
deflection layer 570. Additional details of system 500 are described herein.
Helmet shell 510 is configured to be positioned on a user's head. Helmet
shell 510 may be a helmet shell substantially as described with respect to
helmet shell
110, or may be a helmet substantially as described above with respect to
helmet 340.
The size of helmet shell 510 is selected such that helmet shell 510 can
accommodate
the remaining components of system 500 while still be securely positioned on
the user's
head.
Spacing pad 530 is positioned within the interior of helmet shell 510.
Spacing pad 530 may be a spacing pad substantially as described with respect
to
spacing pad 130. Alternatively, spacing pad 530 may be an impact-resistant pad
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substantially as described above with respect to impact-resistant pad 200.
Likewise,
spacing pad 530 may be formed from any of the materials set forth above with
respect
to spacing pad 130 or impact-resistant pad 200, and may take any of the shapes
described above with respect to spacing pad 130 and/or impact-resistant pad
200.
Alternatively, spacing pad 530 may have any other shape suitable for covering
a space
between the user's head and the helmet shell 510. Spacing pad 530 may also
comprise
an array of raised portions 531 formed on a surface thereof, as described
above with
respect to raised portions 131.
Spacing pad 530 is not adapted to be coupled to the interior of helmet
113 shell 510. In other words, spacing pad 530 remains unconnected to
helmet shell 510
(or from any other component that is connected to helmet shell 510, e.g.,
conventional
helmet padding provided with helmet shell 510). This enables relative movement
between spacing pad 530 and helmet shell 510, which may be important to assist
in
dissipation of the force from impacts, as explained in further detail below
with respect
to deflection layer 570.
Helmet padding system 500 may include a plurality of absorption pads
550 coupled to spacing pad 530. Absorption pads 550 may be substantially the
same
as those described above with respect to absorption pads 150.
Deflection layer 570 is positioned between helmet shell 510 and spacing
pad 530. Deflection layer 570 is formed from a material that is less flexible
(i.e. stiffer)
than spacing pad 530. This enables the hard surface of deflection layer 570 to
deflect a
portion of the force from impacts along a surface thereof, rather than
transmitting that
force through deflection layer 570 to spacing pad 530. In other words, it
assists in
converting forces from impacts into tangential forces (which propagate along
the
surface) as opposed to normal forces (which propagate through the surface to
the
user's head). In an exemplary embodiment, deflection layer 570 comprises a
sheet of
polycarbonate material. Deflection layer 570 may have a shape corresponding to
the
shape of spacing pad 530, such that the deflection layer 570 completely covers
the
space between spacing pad 530 and helmet shell 510.
Deflection layer 570 is also not coupled to the interior of helmet shell
510. This creates a "slip plane" between deflection layer 570 and helmet shell
510, and
enables relative movement between the two components. Put another way, this
allows
independent movement of the user's head (with which spacing pad 530 and
deflection
layer 570 are in contact) and helmet shell 510.
Helmet padding system 500 may also include a plurality of deflection
plates 580. Deflection plates 580 may be coupled to the interior of helmet
shell 510 in
positions such that they slidably abut deflection layer 570. Deflection plates
580 may
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be coupled to helmet shell 510, e.g., with an adhesive. Deflection plates 580
are
formed from the same materials as deflection layer 570. The use of deflection
plates
580 coupled to helmet shell 510 may further promote a sliding interface
between
deflection layer 570 and helmet shell 510, and thereby promote deflecting the
force of
impacts in a tangential direction along deflection layer 570, rather than
through
deflection layer 570 to spacing pad 530.
Helmet padding system 500 may also include a deformation layer 590.
Deformation layer 590 may be positioned between deflection layer 570 and
spacing pad
530. Deformation layer 590 is configured to deform upon experiencing the force
from
io an impact. Deformation layer 590 may undergo elastic (i.e. reversible)
or plastic (i.e.
irreversible) deformation. In an exemplary embodiment, deformation layer 590
comprises a sheet of corrugated plastic material configured to undergo plastic
deformation. As shown in FIG. 12, the sheet of corrugated plastic material may
comprise a pair of plastic surface layers separated by a plurality of plastic
ridges
defining air gaps therebetween. Like deflection layer 570, deformation layer
590 may
have a shape corresponding to the shape of spacing pad 530, such that the
deformation
layer 590 completely covers the space between spacing pad 530 and deflection
layer
570.
Deformation layer 590 may undergo plastic deformation, for example, by
crumpling, bending, fracturing, or other irreversible changes. Accordingly,
deformation
layer 590 may need to be periodically replaced following impacts to helmet
padding
system 500, where such impacts are sufficient to cause significant plastic
deformation
of deformation layer 590.
The above components of helmet padding system 500 may be contained
in a liner (not shown). In particular, a liner may be configured to surround
and contain
spacing pad 530, deflection layer 570, and deformation layer 590, to maintain
their
relative positioning and arrangement. The liner may be formed, for example,
from a
cloth or nylon material to provide a comfortable contact between the user and
the
components of helmet padding system 500.
FIGS. 14A-14D illustrate another exemplary helmet padding system 600
in accordance with aspects of the present invention. Helmet padding system 600
may
be worn by a user during military activities, e.g., under a standard military
helmet. As
a general overview, system 600 includes a frame 610 and a spacing pad 630.
Additional details of system 600 are described herein.
Frame 610 is configured to be positioned on a user's head. Frame 610
comprises a rigid material such as, for example, a plastic or polycarbonate
material.
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The size of frame 610 is selected such that helmet shell 610 can accommodate
spacing
pad 630 while still be securely positioned on the user's head.
Spacing pad 630 is coupled to frame 610. Spacing pad 630 may be a
spacing pad substantially as described with respect to spacing pad 130, and/or
may be
formed from any of the materials described with respect to spacing pad 130. In
particular, spacing pad 630 comprises a central portion 632 and a plurality of
extending
portions 634 projecting outward from the central portion 632. The plurality of
extending portions 634 are fixed to frame 610.
As shown in= FIGS. 14A and 14B, each extending portion 630 has an end
io portion with a greater width than a portion of the respective extending
portion coupled
to central portion 632. Specifically, extending portions 630 get wider as they
extend
outwardly from central portion 632. The end portions of extending portions 634
are
fixed to frame 610.
In an exemplary embodiment, frame 610 comprises a groove 612, as
shown in FIG. 14B. The end portions of each of the plurality of extending
portions 634
are inserted within groove 612. The end portions of the plurality of extending
portions
634 may be additionally secured to the frame via one or more attachment
mechanisms.
Suitable attachment mechanisms 615 include, for example, rivets, adhesives, or
stitching.
Frame 610 may be configured to be coupled to a helmet, as shown in
FIG. 14D. In an exemplary embodiment, frame 610 is configured to be coupled to
a
standard-issue military helmet. The standard-issue military helmet includes a
plurality
(e.g. four) pre-arranged mounting points, such as drill holes, in the helmet.
In this
embodiment, frame 610 includes a plurality of through holes 614 positioned to
align
with the pre-arranged mounting points in the military helmet. This may
desirably
simplify the attachment of frame 610 to the helmet. Spacing pad 630 is fixed
to frame
610 in such a way that spacing pad does not contact the helmet when frame 610
is
coupled to the helmet.
In one exemplary embodiment, frame 610 has a ring shape, as shown in
FIGS. 148 and 14C. The plurality of extending portions 634 extend upward from
frame
610, such that central portion 623 is positioned above frame 610. This creates
a cavity
within frame 610 in which the top of the user's head is positioned during use.
FIGS. 15A-15C illustrate another exemplary helmet padding system 700
in accordance with aspects of the present invention. The helmet padding system
700 is
substantially the same as helmet padding system 600, and only the differences
between those two embodiments will be described hereinafter.
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In an exemplary embodiment, frame 710 of helmet padding system 700
has a dome shape, as shown in FIGS. 15A-15C. The standard-issue military
helmet
includes a plurality (e.g. four) pre-arranged mounting points, such as drill
holes, in the
helmet. In this embodiment, frame 710 includes a plurality of through holes
714
positioned to align with the pre-arranged mounting points in the military
helmet.
Spacing pad 730 is positioned within the dome, and may be adhered to
an inner surface of the dome. The dome-shaped frame 710 includes a plurality
of
ridges 716 formed on an outer surface thereof. As shown in FIGS. 15A and 15B,
ridges
716 extend along frame 710 from edge to edge through a top portion of frame
710.
to When dome-shaped frame 710 is coupled to a helmet, frame 710 contacts
the helmet
only along the outermost surfaces of the plurality of ridges 716. This may be
desirable
in order to minimize the transfer of impact force from the helmet to frame
710. In this
embodiment, frame 710 may also include a plurality of straps 718 for enhancing
fit and
comfort of system 700 when worn by a user, as shown in FIG. 15C.
Helmet padding systems 600 and 700 may also include a deformation
layer. The deformation layer may be a layer substantially as described with
respect to
deformation layer 590. In one embodiment, the deformation layer is positioned
between the frame and the spacing pad. In an alternative embodiment, the
deformation layer is positioned such that it is between the frame and the
helmet when
the frame is coupled to the helmet.
As explained above with respect to FIG. 13, the helmet padding systems
800, 900, 1000 of the present invention may be used with baseball caps. In
accordance with another aspect of the present invention, a helmet padding
system
usable with such a baseball-style cap is disclosed. New FIGS. 16-18 disclose
alternative embodiments of such a system.
The baseball cap of this system has the style of a normal baseball cap
except on sides of the cap. The body of the cap may be formed from flexible
material
such as cotton or synthetic textiles. The rear of the cap may be fitted to the
user's
head, or may include a conventional adjustable strap. As shown in FIG. 16, the
side
810 of the cap extends downward to cover the user's temple, and at least a
portion
(preferably at least 50%) of the user's ear. A downward extended portion is
formed on
both sides of the cap. As shown in FIG. 16, the downward extended portion may
extend across the rear of the cap. Alternatively, as shown in FIGS. 17 and 18,
the
downward extended portion may end (or grow more narrow) across the rear of the
cap.
As shown in FIG. 16, the cap body may include an opening 820 in the area of
the user's
ear. The opening may be desirable in order to promote aeration within the cap,
and to
provide the user better hearing.
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Within the cap, a spacing pad is provided. In an exemplary embodiment,
spacing pad 130d illustrated in FIG. 13 is provided. Alternatively, the cap
may include
any of the spacing pads and accompanying components described herein. Still
further,
this system may use conventional foam padding in place of the spacing pad.
5 The shape of the spacing pad may be selected to maximize coverage
of
the user's head while minimizing interference with the user's comfort (e.g.,
by
obstructing the user's hearing). In an exemplary embodiment, the spacing pad
has one
extending portion that extends from the top of the cap to a position forward
of the
user's ear, to cover the user's temple, and another extending portion that
extends from
10 the top of the cap to a position rearward of the user's ear, to cover
the base of the
user's skull behind their ear. The spacing pad is shaped to leave a gap in the
area of
the user's ear, to avoid obstructing the user's hearing.
To protect the area of the user's ear, the cap may include a rigid frame.
The rigid frame may be formed, for example, from rigid plastic. In an
exemplary
15 embodiment, the rigid frame comprises a plurality of rigid outer members
extending
along the periphery of the gap (adjacent the edges of the spacing pad). The
frame may
have a substantially round, rectangular, or triangular shape. The frame
further
comprises an open area between the rigid outer members. The open area in the
central
portion of the rigid frame is desirable in order to avoid obstructing the
user's hearing.
The cap may also include a rigid liner around a peripheral edge of the
cap. In an exemplary embodiment, the rigid liner comprises a thin, rigid
structure
extending around the peripheral edges of the cap. The rim may be formed, for
example, from rigid plastic. The rim may desirably be positioned within a fold
or
pocket of the outer cloth body of the cap, in order to enhance the user's
comfort.
FIGS. 19A and 19B illustrate an exemplary helmet padding system 1100
in accordance with aspects of the present invention. Helmet padding system
1100 may
be worn by a user during an athletic activity. Desirably, helmet padding
system 1100
may be worn under another piece of headgear, such as a baseball cap. As a
general
overview, system 1100 includes a main portion 1110 and a removable portion
1180.
FIG. 19A shows a view of helmet padding system 1100 with removable portion
1180
coupled to main portion 1110, and FIG. 19B shows a view of helmet padding
system
with removable portion 1180 separated from main portion 1110. Additional
details of
system 1100 are described herein.
When system 1100 is worn under a baseball cap having a rear cut-out
(e.g., for an adjustable strap), removable portion 1180 is desirably located
at the same
position as the rear cut-out. In normal use, removable portion 1180 remains
coupled
to main portion 1110, and provides impact protection to the user in the area
of the rear
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cut-out, in substantially the same manner as main portion 1110. However, a
user may
also choose to remove removable portion 1180 during use. Removal of removable
portion 1180 from main portion 1110 opens up an area of the user's head
directly
beneath the cut-out of the baseball cap. This may be particularly desirable
for users of
system 1100 having long hair, who for comfort or other reasons wish their hair
to
extend through the air of the rear cut-out of the baseball cap. In other
words, removal
of removable portion 1180 desirably allows certain users to utilize the rear
cut-out of
their baseball cap as they normally would if they were not wearing a helmet
padding
system underneath their baseball cap.
Main portion 1110 is configured to be positioned on a user's head. Main
portion 1110 may include a plurality of different subcomponents similar to the
layers of
the various helmet padding systems described herein. In an exemplary
embodiment,
main portion 1110 includes a spacing pad (not shown), a plurality of
absorption pads
1150, and a deflection layer 1170.
The spacing pad of main portion 1110 is positioned within the interior of
main portion 1110. The spacing pad may be a spacing pad substantially as
described
with respect to spacing pad 130. Alternatively, the spacing pad may be an
impact-
resistant pad substantially as described above with respect to impact-
resistant pad 200.
Likewise, the spacing pad may be formed from any of the materials set forth
above
zo with respect to spacing pad 130 or impact-resistant pad 200, and may
take any of the
shapes described above with respect to spacing pad 130 and/or impact-resistant
pad
200.
In a particularly suitable embodiment, the spacing pad of main portion
1110 has a shape and structure corresponding to spacing pad 130d, as shown in
FIG.
13. As set forth above, both system 1100 and spacing pad 130d may be intended
for
use in a baseball cap having a rear cut-out (e.g., for an adjustable strap).
In this
embodiment, the spacing pad of main portion 1110 has a shortened extending
portion
having a rounded edge relative to the other extending portions, as shown in
FIG. 13.
In helmet padding system 1100, this extending portion is positioned to extend
toward
the location of the removable portion 1180 of system 1100. Accordingly, the
spacing
pad of main portion 1110 does not extend into or otherwise interfere with the
area
covered by removable portion 1180. System 1100 may also include a separate
spacing
pad having the same material coupled to the interior of removable portion 1180
Helmet padding system 1100 may include a plurality of absorption pads
1150 coupled to the spacing pad and/or deflection layer 1170. Absorption pads
1150
may be substantially the same as those described above with respect to
absorption
pads 150 (shown in FIGS. 1 and 3). As shown in FIG. 19C, system 1100 may
include
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absorption pads 1150 on both main portion 1110 and removable portion 1180. One
of
ordinary skill in the art will understand that the number and positioning of
absorption
pads 1150 shown in FIG. 19C is done for the purposes of illustration, and is
not
intended to be limiting.
Deflection layer 1170 is positioned along the exterior of main portion
1110. Deflection layer 1170 may be a deflection layer substantially as
described with
respect to deflection layer 570 (shown in FIG. 12). In an exemplary
embodiment,
deflection layer 1170 is formed from polycarbonate material. Deflection layer
1170 is
shaped and sized so as to accommodate the components within (including the
spacing
1() pad and absorption pads 1150) while comfortably fitting on a user's
head. Deflection
layer 1170 includes a cut-out portion 1172 (similar to the spacing pad) having
a shape
corresponding to the shape of the conventional rear cut-out of a baseball cap.
Cut-out
portion 1172 is sized to accommodate the removable portion 1180 therein in
order to
form (with removable portion 1180) an approximately continuous dome shape on
the
top of the user's head. Deflection layer 1170 may further include one or more
projecting sections 1174 to enhance the ability of system 1100 to dissipate
the force of
impacts to the user's head.
Deflection layer 1170 is not adapted to be coupled to the interior of the
baseball cap. As with deflection layer 570, this creates a "slip plane"
between
deflection layer 570 and the baseball cap, and enables relative movement
between the
two components. Put another way, this allows independent movement of the
user's
head (with which the spacing pad and deflection layer 1170 are in contact) and
the
baseball cap.
Removable portion 1180 is configured to be coupled to and removable
from main portion 1110. Removable portion 1180 may be formed from
substantially
the same materials as main portion 1110. In particular, removable portion 1180
may
include a spacing pad, absorption pad, and deflection layer the same as those
used in
the formation of main portion 1110. Removable portion 1180 is shaped to
correspond
to the shape of the conventional rear cut-out of a baseball cap, and is sized
to be
received with the cut-out portion 1172 of the deflection layer 1170 of main
portion
1110.
Removable portion 1180 may be coupled to main portion 1110 by a
number of different mechanisms. In an exemplary embodiment, removable portion
1180 is frictionally coupled to main portion 1110, as shown in FIGS. 19A and
19B. In
this embodiment, removable portion 1180 includes tabs 1182 adapted to slide
along
the outer surface of main portion 1110, and tabs 1184 adapted to slide along
the inner
surface of main portion 1110. Tabs 1182 and 1184 sandwich main portion 1110
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therebetween, thereby creating a friction fit that holds removable portion
1180 in place
against main portion 1110.
Alternatively or additionally, removable portion 1180 may be coupled to
main portion 1110 using one or more snapping mechanisms, as shown in FIGS. 19C
and 19D. In this embodiment, removable portion 1180 includes a projection 1186
position to mate with a corresponding aperture 1188 on main portion 1110. When
removable portion 1180 is properly positioned against main portion 1110,
projection
1186 is received within aperture 1188, thereby snapping removable portion 1180
in
place against main portion 1110. The snapping mechanism may be configured to
io frictionally maintain the connection until a predetermined pressure is
applied to unsnap
removable portion 1180 from main portion 1110.
The above embodiments allow removable portion 1180 to be both
uncoupled from and recoupled to main portion 1110. However, in some
embodiments,
removable portion 1180 may not be permanently recoupled to main portion 1110.
In
one embodiment, removable portion 1180 may be attached to main portion through
one or more weakened, thinned, or perforated pieces of material (e.g., the
material of
deflection layer 1170). Removable portion 1180 may then be permanently removed
from main portion 1110 by breaking this area of weakened material.
FIGS. 20A and 20B illustrate an alternative embodiment 1200 of helmet
padding system 1100. As shown in FIGS. 20A and 20B, the deflection layer of
helmet
padding system 1200 has a more streamlined outer surface, without the
projecting
sections of system 1100. This may enable helmet padding system 1200 to more
easily
fit within or underneath a baseball cap, as shown in FIG. 21.
As shown in FIG. 20B, removable portion 1280 is frictionally coupled to
main portion 1210 by a plurality of outer surface tabs 1282 and a plurality of
inner
surface tabs 1284 adapted to slide along the inner surface of main portion
1110. Tabs
1282 and 1284 sandwich main portion 1210 therebetween, thereby creating a
friction
fit that holds removable portion 1280 in place against main portion 1210. When
system 1200 is used underneath a baseball cap having a rear cut-out, removable
portion 1280 may optionally be removed to allow users with long hair to extend
their
hair out through the cap's rear cut-out.
FIGS. 22 and 23 illustrate another exemplary helmet padding system
1300 in accordance with aspects of the present invention. As with systems 1100
and
1200, helmet padding system 1300 may be worn by a user during an athletic
activity,
and desirably, may be worn under another piece of headgear, such as a baseball
cap.
Generally, system 1300 includes the same components set forth above with
respect to
system 1100. Additional features forming part of system 1300 are set forth
below.
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Main portion 1310 of system 1300 includes a cushioning portion 1390.
Cushioning portion 1390 extends into a cut-out area of deflection layer 1370.
In an
exemplary embodiment, cushioning portion 1390 extends into a cut-out area
along a
centerline of deflection layer 1370 from a front-most edge of deflection layer
1370
toward a rearward portion of deflection layer 1370. Cushioning portion 1390
separates
opposed portions of deflection layer 1370 in order to enable movement of one
side of
deflection layer 1370 relative to the other side of deflection layer 1370.
Such
movement may desirably assist system 1300 in dissipating the force of impacts
to a
user's head.
Cushioning portion 1390 is formed from a material that is more flexible
and/or compressible than the material of deflection layer 1370. In an
exemplary
embodiment, cushioning portion is formed from the same materials as absorption
pads
150 or 1150.
The length of cushioning portion 1390 may be adjusted to optimize the
force-dissipating effect provided. In one exemplary embodiment, cushioning
portion
1390 extends along the entire length of deflection layer 1370, from the front-
most edge
to the rear edge of cut-out portion, as shown in FIG. 22. In an alternative
embodiment, cushioning portion 1390 does not extend along the entire length of
deflection layer 1370, but terminates before the rear edge, as shown in FIG.
23.
Additionally, the width of cushioning portion 1390 may be adjusted to optimize
the
force-dissipating effect provided. In an exemplary embodiment, the width
across
cushioning portion 1390 may be from about 0.3 inches to about 3.0 inches.
FIGS. 24A-24C illustrate an exemplary helmet padding system 1400 in
accordance with aspects of the present invention. Helmet padding system 1400
may
be worn by a user during an athletic activity. Desirably, helmet padding
system 1400
may be worn under another piece of headgear, such as a baseball cap, knit
winter cap,
beanie, or other piece of aesthetic headwear. As a general overview, system
1400
includes a rigid shell 1410 and a spacing pad 1440. Additional details of
system 1400
are described herein.
Rigid shell 1410 is configured to cover the top of a user's head. Rigid
shell 1410 is sized to be worn under a baseball cap. Accordingly, it may be
desirable
that rigid shell 1410 be formed from a thin, rigid material. In an exemplary
embodiment, rigid shell 1410 is formed from a polycarbonate material, as
described
above with respect to deflection layer 1170. The material may have a thickness
of less
than approximately 5 mm, and more desirably, less than approximately 3.5 mm.
Forming rigid shell 1410 with a low profile (i.e. thin size) is desirable to
promote use of
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helmet padding system 1400 by eliminating interference with the aesthetic
features of
the headgear (e.g., baseball cap) worn on top of rigid shell 1410.
Rigid shell 1410 includes a body portion 1420 and a pair of side portions
1430. Body portion 1420 has a lower front edge 1421 extending between the pair
of
s side portions 1430. When worn under a baseball cap, lower front edge 1421
is
positioned adjacent the brim of the baseball cap. Body portion 1420 further
includes a
lower rear edge 1422 extending between the pair of side portions 1430 opposite
lower
front edge 1421.
In one embodiment, lower rear edge 1422 of body portion 1420 has
, io approximately the same height as lower front edge 1421, as shown in
FIG. 24A. In this
embodiment, lower rear edge extends along approximately the same
circumferential
line (around the user's head) as lower front edge 1421. In this embodiment,
when
rigid shell 1410 is worn under a baseball cap (such as a fitted baseball cap)
lower rear
edge 1422 is positioned adjacent the lower edge of the cap.
15 In an alternative embodiment, lower rear edge 1422 extends
down the
user's head along with side portions 1430, as shown in FIGS. 25 and 26. In
this
embodiment, lower rear edge 1422 extends along approximately a same
circumferential line as the lower edges of side portions 1430. In this
embodiment,
when rigid shell 1410 is worn under a baseball cap (such as a fitted baseball
cap) lower
20 rear edge 1422 extends below the lower edge of the cap.
Body portion 1420 may include at least one opening therein. The
opening preferably allows breathability between the interior of rigid shell
1410 (i.e., the
area adjacent the user's head) and the exterior of rigid shell 1410. In an
exemplary
embodiment, body portion 1420 includes a plurality of openings 1423, with at
least one
opening positioned between each side portion 1430 and an apex of rigid shell
1410, as
shown in FIG. 24A.
Body portion 1420 may also include one or more ridges along a surface
thereof. In an exemplary embodiment, body portion 1420 includes an elevated
ridge
1424 extending from an area adjacent lower front edge 1421 over the apex of
body
portion 1420 to an area adjacent lower rear edge 1422, as shown in FIG. 24C.
Ridge
1424 may provide additional structural stability to rigid shell 1410, thereby
allowing
shell 1410 to better dissipate the force of impacts. Ridge 1424 may further
provided
additional space between rigid shell 1410 and the user's head, adding to
comfort and
breathability for the user.
Body portion 1420 may also include a pair of cutouts 1425 on ends of
front edge 1421, as shown in FIG. 24B. Cutouts 1425 are provided between front
edge
1421 and side portions 1430. Body portion 1420 may further include a pair of
cutouts
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1425 on the ends of rear edge 1422, as shown in FIG. 24C. Cutouts 1425
desirably
provide a path for coupling rigid shell 1410 to the interior of a baseball
cap, as will be
described below. It will be understood by one of ordinary skill in the art
that the shape
of cutouts 1425 shown in FIG. 248 is provided for the purposes of
illustration, and is
not intended to be limiting. For example, cutouts 1425 may be formed with a
triangular or round shape without departing from the scope of the present
invention.
Side portions 1430 extend downward below the lower front edge 1421 of
body portion 1420, as shown in FIGS. 24A-24C. Side portions 1430 are sized to
cover
at least a portion (preferably at least 50%) of the user's ear when rigid
shell 1410 is
worn by the user. Side portions 1430 are also desirably sized to cover the
user's
temples when rigid shell 1410 is worn by the user. To this end, each side
portion 1430
may have a circumferential length (along the side of the user's head) that is
longer
than the distance (or height) to which side portions 1430 extend below lower
front
edge 1421.
Side portions 1430 may include at least one opening therein. The
opening may preferably be positioned over the user's ear when rigid shell 1410
is worn
by the user. Such positioning allows the user to hear his or her surroundings
while
maintaining protection to the user's ear area from impacts. In an exemplary
embodiment, each side portion 1430 comprises a set of spaced apart, elongated
openings 1431, as shown in FIG. 24A.
Side portions 1430 may also include one or more flared portions. In an
exemplary embodiment, side portions 1430 include flared portions 1432
extending
outward relative to a surface of body portion 1420, as shown in FIG. 24C.
Flared
portions 1432 may provide additional space between rigid shell 1410 and the
user's
head and ears, adding to the user's comfort. When rigid shell 1410 is worn
beneath a
baseball cap, flared portions 1432 may include all of side portions 1430 that
are
positioned below the baseball cap.
Side portions 1430 may also include one or more attachment points.
During use of helmet padding system 1400, it may be desirable to attach one or
more
accessories (such as straps, goggles, headphones or other accessories) to
system 1400.
Accordingly, rigid shell 1410 may include one or more attachment points
designed to
facilitate the attachment of appropriate accessories to the user's athletic
activity. Such
attachment points are preferably positioned on side portions 1430 so that they
can be
accessed even when rigid shell 1410 is worn underneath a baseball cap. In an
exemplary embodiments, side portions 1430 include a pair of through-holes 1433
on
either end thereof, as shown in FIG. 24A. Through-holes 1433 provide
attachment
points for a strap (e.g., a chin strap) to be attached to rigid shell 1410.
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Spacing pad 1440 is positioned within the interior of rigid shell 1410, as
shown in FIG. 27. The spacing pad may be a spacing pad substantially as
described
with respect to spacing pad 130. Alternatively, the spacing pad may be an
impact-
resistant pad substantially as described above with respect to impact-
resistant pad 200.
Likewise, the spacing pad may be formed from any of the materials set forth
above
with respect to spacing pad 130 or impact-resistant pad 200, and may take any
of the
shapes described above with respect to spacing pad 130 and/or impact-resistant
pad
200.
In a particularly suitable embodiment, the spacing pad 1440 includes a
first portion 1441 extending circumferentially around a lower portion of rigid
shell 1410,
e.g., adjacent lower front edge 1421:and lower rear edge 1422, as shown in
FIG. 27.
In this embodiment, spacing pad 1440 includes a second portion 1442 extending
from
an area adjacent lower front edge 1421 over the apex of body portion 1420 to
an area
adjacent lower rear edge 1422.
Where helmet padding system 1400 is used with a fitted baseball cap,
rigid shell 1410 may have a continuous, uninterrupted rear body portion.
However,
when helmet padding system 1400 is used with an adjustable baseball cap, rigid
shell
1410 may include a cutout as shown in FIGS. 24A-26, and as set forth below.
Rigid shell 1410 may include a cutout 1426 in an area of body portion
1420 opposite lower front edge 1421. When rigid shell 1410 is worn beneath a
baseball cap, cutout 1426 is provided in an area of body portion 1420 adjacent
a rear
of the baseball cap. In this embodiment, the baseball cap may be an adjustable
baseball cap an opening for accommodating the adjustable strap. Accordingly,
cutout
1426 has a shape corresponding to the shape of the opening in the rear of the
adjustable baseball cap.
When rigid shell 1410 incorporates a cutout 1426, helmet padding
system 1400 may further comprise a removable portion 1460 configured to fit
within
cutout 1426 of rigid shell 1410. Removable portion 1460 is formed from the
same
material as rigid shell 1410, in order to provide similar protection from the
force of
impacts. Thus, when removable portion 1460 is coupled to rigid shell 1410, the
components form an approximately continuous dome shape on the top of the
user's
head.
Both cutout 1426 and removable portion 1460 may have a shape
different from the semicircular cutout shape shown in FIG. 25. For example, as
shown
in FIG. 26, cutout 1426 and removable portion 1460 may cover a substantially
larger
portion of body portion 1420 of rigid shell 1410. Providing a larger cutout
1426 and
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removable portion 1460 may be desirable in order to provide a size or contour
adjustability to rigid shell 1410 to accommodate users having different sized
heads.
Removable portion 1460 is configured to be coupled to and removable
from rigid shell 1410. Removable portion 1460 may be coupled to rigid shell
1410 by a
number of different mechanisms, as described above with respect to removable
portion
1180. In an exemplary embodiment, removable portion 1460 is frictionally
coupled to
rigid shell 1410, as shown in FIG. 24C. In this embodiment, removable portion
1460
includes tabs 1461 adapted to slide along the outer surface of rigid shell
1410, and tabs
1462 adapted to slide along the inner surface of rigid shell 1410, as shown in
FIG. 25.
Tabs 1461 and 1462 sandwich rigid shell 1410 therebetween, thereby creating a
friction fit that holds removable portion 1460 in place against rigid shell
1410.
Removable portion 1460 may be coupled to rigid shell 1410 using alternative
mechanisms as discussed above with respect to removable portion 1180.
Where rigid shell 1410 does not include a cutout as set forth above, body
is portion 1420 may nonetheless include one or more slits in a lower
portion thereof to
accommodate users having different sized heads. The inclusion of slits in
rigid shell
1410 may allow for adjustability of size between opposite sides of body
portion 1420
without opening gaps that could negatively impact the protection provided by
rigid shell
1410. In an exemplary embodiment, body portion 1420 includes a vertical slit
1427 at
an approximate midpoint of a rear portion of body portion 1420 extending
upward from
lower rear edge 1422, as shown in FIG. 28A. In another exemplary embodiment,
body
portion 1420 includes a J-shaped slit 1428 along the rear portion of body
portion 1420,
as shown in FIG. 28B. As shown in FIGS 28A and 28B, body portion 1420 may
include
a tab 1429 on one side of the slit 1427 or 1428 that extends overtop a surface
of the
body portion on the other side of the slit 1427 or 1428. Tab 1429 desirably
allows the
sides of body portion 1420 to move circumferentially with respect to one
another
(depending on the size of the user's head), while preventing relative inward
or outward
movement of the opposing sides of body portion 1420.
As shown in FIG. 29, helmet padding system 1400 may further include a
baseball cap 1480. Baseball cap 1480 has a body portion 1481 and a brim
portion
1482. As set forth above, rigid shell 1410 is configured to be worn beneath
baseball
cap 1480. Side portions 1430 of rigid shell 1410 are configured to extend
downward
below the lower edge of body portion 1481 of baseball cap 1480, as shown in
FIG. 29.
In this embodiment, side portions 1430 provide protection for the user's head
beneath
the lower edge of conventional baseball caps, including the user's temples and
ears,
which are normally left uncovered by conventional baseball caps.
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Additionally, the extension of side portions 1430 beneath the lower edge
of baseball cap 1480 provides a visual indication to others that the user is
wearing
increased head protection relative to that offered by a normal baseball cap.
Such visual
indication may be useful, e.g., to promote compliance with requirements of
head
protection during athletic activities.
Baseball cap 1480 may include an interior flap of material adjacent the
front or rear lower edges thereof. Such a flap of material may be used for
providing a
connection between baseball cap 1480 and rigid shell 1410. In an exemplary
embodiment, body portion 1420 may also include a pair of cutouts 1425, as
shown in
FIG. 24B. In this embodiment, the flap on baseball cap 1480 passes through
cutouts
1425, such that a portion of the flap is positioned adjacent an interior
surface of rigid
shell 1410 (as opposed to outside of rigid shell 1410). Tucking a portion of
the flap
through cutouts 1425 may be useful to secure baseball cap1480 to rigid shell
1410,
and to provide additional comfort and/or sweat absorbency to the user's
forehead.
FIGS. 30A and 30B illustrate an alternative embodiment 1500 of helmet
padding system 1200 in accordance with aspects of the present invention.
Helmet
padding system 1500 may be worn by a user during an athletic activity. Like
helmet
padding system 1200, helmet padding system 1500 may be worn under another
piece
of headgear, such as a baseball cap. As a general overview, system 1500
includes a
main portion 1510 and an opening 1580. Helmet padding system 1500 includes
substantially the same features as helmet padding system 1100 and/or 1200,
except as
described herein.
Main portion 1510 is configured to be positioned on a user's head. Main
portion 1510 may include a plurality of different subcomponents corresponding
to the
layers of the various helmet padding systems described herein. In an exemplary
embodiment, main portion 1510 includes a spacing pad, a plurality of
absorption pads,
and a deflection layer. Other components or layouts for dissipating the force
of impacts
may be selected based on the various embodiments described herein.
As shown in FIG. 30B, main portion 1510 of helmet padding system 1500
has a streamlined outer surface similar in design to helmet padding system
1200. This
streamlined outer surface may enable helmet padding system 1500 to more easily
fit
within or underneath a baseball cap, as described above. The streamlined outer
surface may include one or more elevated ridges 1512 extending along the
surface
thereof. As shown in FIG. 30B, the elevated ridges 1512 extend in a direction
from a
front of the user's head to the back of the user's head. These ridges provide
additional
structural support to main portion 1510, and assist in dissipating the force
of impacts
to the user's head.
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Unlike systems 1100 and 1200, the opening 1580 of helmet padding
system 1500 does not extend down to the lower edge of main portion 1510.
Instead,
main portion 1510 includes a bridge 1514 extending below opening 1580, as
shown in
FIGS. 30A and 30B. Thus, opening 1580 is completely surrounded by parts of
main
5 portion 1510. This layout improves the structural stability of helmet
padding system
1500, by limiting relative movement of the left and right sides of main
portion 1510
relative to one another. For example, bridge 1514 may be formed from a
substantially
rigid material (such as the deflection layer material described above) in
order to
prevent inward and outward movement of the left and right sides of main potion
1510
io relative to one another.
Bridge 1514 also allows helmet padding system 1500 to maintain a
continuous, uninterrupted lower edge, as shown in FIG. 30B. This continuous
lower
edge may improve protection and comfort for the user. Moreover, bridge 1514
may
include one or more of the interior padding layers described herein to improve
impact
is resistance. For example, the main portion 1510 of helmet padding system
1500 may
include a continuous padding layer along the entire lower circumferential edge
thereof
to improve protection of the user from impacts.
When system 1500 is worn under a baseball cap having a rear cut-out
(e.g., for an adjustable strap), opening 1580 is desirably located at the same
position
20 as the rear cut-out. Thus, opening 1580 reveals an area of the user's
head directly
beneath the cut-out of the baseball cap. This may be particularly desirable
for users of
system 1500 having long hair, who for comfort or other reasons wish their hair
to
extend through the rear cut-out of the baseball cap. In other words, opening
1580
desirably allows certain users to utilize the rear cut-out of their baseball
cap as they
25 normally would if they were not wearing a helmet padding system
underneath their
baseball cap.
System 1500 may further include a removable plate 1582 sized to fit
within opening 1580, as shown in FIGS. 31A-31C. Removable plate 1582 may have
an
approximately oval shape corresponding to the shape of opening 1580, in order
to be
easily received within and fill opening 1580. When received within the
opening,
removable plate 1582 provides impact protection to the user in the area of
opening
1580, in substantially the same manner as main portion 1510. To this end,
removable
plate 1582 may be formed from the same material as main portion 1510 of system
1500, and may include one or more of the interior padding layers described
herein to
improve impact resistance.
Removable plate 1582 may be coupled to the main portion 1510 when it
is received in opening 1580 using any of the attachment methods set forth
above with
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respect to removable portions 1180 and 1280. In an exemplary embodiment, the
removable plate includes a plurality of snapping mechanisms 1584 that snap
onto main
portion 1510 of system 1500, as shown in FIG. 31C. Snapping mechanisms 1584
may
snap onto main portion 1510 on an outer surface thereof and/or on an inner
surface
thereof. = To this end, snapping mechanisms may be formed as tabs that are
configured
to extend along an outer or inner surface of main portion 1510 when removable
plate
1582 is positioned within opening 1580. Removable plate 1582 can then be
removed
from main portion 1510 at the user's discretion.
In an exemplary embodiment, removable plate 1582 includes a pair of
io outer tabs 1586 extending from an upper edge, and an outer ridge 1588
extending
along the lower edge thereof. Tabs 1586 and ridge 1588 are positioned to rest
on or
contact an outer surface of main portion 1510, as shown in FIG. 31A. Removable
plate
1582 further includes at least one inner tab 1589 extending from the upper
edge and
positioned to rest on or contact an inner surface of main portion 1510. In
this
embodiment, to couple removable plate 1582 to main portion 1510, plate 1582 is
slid
into opening 1580 from a lower angle, in order to sandwich main portion 1510
between
tabs 1586 and 1589, and allow ridge 1588 to rest on the lower edge of opening
1580,
as shown in FIG. 31C.
FIGS. 32A and 32B illustrate an alternative embodiment 1600 of helmet
padding system 1400 in accordance with aspects of the present invention.
Helmet
padding system 1600 may be worn by a user during an athletic activity. Like
helmet
padding system 1400, helmet padding system 1600 may be worn under another
piece
of headgear, such as a baseball cap. As a general overview, system 1600
includes a
rigid shell 1610, a spacing pad, and a facemask 1690. Helmet padding system
1600
includes substantially the same features as helmet padding system 1400, except
as
described herein.
Rigid shell 1610 is configured to cover the top of a user's head. Rigid
shell 1610 is sized to be worn under a baseball cap. Rigid shell 1610 includes
a body
portion 1620 and a pair of side portions 1630. Body portion 1620 has a lower
front
edge 1621 extending between the pair of side portions 1630. Body portion 1620
further includes a lower rear edge 1622 extending between the pair of side
portions
1630 opposite lower front edge 1621.
When worn under a baseball cap, lower front edge 1621 extends below
the brim of the baseball cap. In an exemplary embodiment, lower front edge
1621 of
rigid shell 1610 extends approximately one inch below the brim of the baseball
cap.
This protruding lower front edge 1621 may be desirable in order to provide
added
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27
protection to the user, as well as to provide a location for attaching
facemask 1690, as
will be discussed below.
As shown in FIG. 32A, lower rear edge 1622 of body portion 1620
extends down the user's head along with side portions 1630. In this
embodiment,
lower rear edge 1622 extends along approximately a same circumferential line
as the
lower edges of side portions 1630. In this embodiment, when rigid shell 1610
is worn
under a baseball cap (such as a fitted baseball cap) lower rear edge 1622
extends
below the lower edge of the cap, in order to provide additional protection to
the neck of
the user.
Body portion 1620 may also include a pair of cutouts 1625 on ends of
front edge 1621., one of which is shown in FIG. 32B. Cutouts 1625 are provided
between front edge 1621 and side portions 1630. It will be understood by one
of
ordinary skill in the art that the shape of cutouts 1625 shown in FIG. 24B is
provided
for the purposes of illustration, and is not intended to be limiting.
Side portions 1630 extend downward below the lower front edge 1621 of
body portion 1620, as shown in FIGS. 32A and 32BC. Side portions 1630 are
sized to
cover at least a portion (preferably at least 50%) of the user's ear when
rigid shell
1610 is worn by the user. Side portions 1630 are also desirably sized to cover
the
user's temples when rigid shell 1610 is worn by the user.
Side portions 1630 may also include one or more attachment points.
attachment points designed to facilitate the attachment of appropriate
accessories to
the user's athletic activity. Such attachment points are preferably positioned
on side
portions 1630 so that they can be accessed even when rigid shell 1610 is worn
underneath a baseball cap.
In an exemplary embodiment, side portions 1630 include one or more
grooves 1631. Grooves 1631 provide attachment points for facemask 1690 to be
coupled to rigid shell 1610. In a preferred embodiment, lower front edge 1621
also
includes one or more grooves 1631 for coupling facemask 1690 to rigid shell
1610.
Groove 1631 on lower front edge 1621 may be accessible to facemask 1690
without
removing the user's cap due to lower front edge 1621 extending below the lower
edge
of the brim of the cap, as described above.
In another exemplary embodiment, side portions 1630 include one or
more snaps 1633. Snaps 1633 provide attachment points for a strap (e.g., a
chin
strap) to be attached to rigid shell 1610. Snaps 1633 may be movable within
slots on
side portions 1630 in order to adjust the fitting of the chin strap.
Rigid shell 1610 may include a cutout 1626 in an area of body portion
1620 opposite lower front edge 1621. When rigid shell 1610 incorporates a
cutout
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1626, helmet padding system 1600 may further comprise a removable portion 1660
configured to fit within cutout 1626 of rigid shell 1610. Removable portion
1660 is
formed from the same material as rigid shell 1610, in order to provide similar
protection from the force of impacts.
Facemask 1690 is configured to protect the user's face from impacts or
projectiles (such as baseballs or softballs) commonly in play during the
course of an
athletic activity. Facemask 1690 may be permanently coupled to rigid shell
1610, or
may be removably coupled to rigid shell 1610. Preferably, facemask 1690 is
removable
from rigid shell 1610 without removable of rigid shell 1610 from the user's
head, and
without removing any components from rigid shell 1610. In this manner, that
facemask 1690 need not be worn throughout an entire athletic activity, and may
be
removed (e.g., when impacts to a user's face are not likely to occur) without
removal of
the user's baseball cap or the remaining components of system 1600.
In an exemplary embodiment, facemask 1690 is formed from a plurality
is of rigid bars 1692 that protect the user's face without substantially
obstructing the
user's vision. Bars 1692 may have portions sized to mate with corresponding
attachment points on rigid shell 1610 in order to couple facemask 1690 to
rigid shell
1.610. In a preferred embodiment, one or more portions of bars 1692 are sized
to mate
with corresponding grooves 1631 formed on side portions 1630 and/or on lower
front
edge 1621. Grooves 1.631 are sized to provide a snug, secure fit to the
portions of bars
1692, while allowing facemask 1690 to be removed (e.g., by sliding) from
grooves
1631 when facemask 1690 is not in use.
System 1600 may further include a chin strap 1694. Chin strap 1694 is
configured to secure system 1600 on the user's head during the course of an
athletic
activity. Chin strap 1694 has ends which are coupled to the respective side
portions
1630 of rigid shell 1610, and is sufficiently long to circle underneath the
user's chin
when rigid shell 1610 is worn by the user. Chin strap 1694 may be permanently
coupled to rigid shell 1610, or may be removably coupled to rigid shell 1610.
Preferably, chin strap 1694 is removable from rigid shell 1610 without
removable of
rigid shell 1610 from the user's head, and without removing any components
from rigid
shell 1610. In this manner, that chin strap 1694 need not be worn throughout
an
entire athletic activity, and may be removed (e.g., when the user is not
active engaged
in the athletic activity) without removal of the user's baseball cap or the
remaining
components of system 1.600.
In an exemplary embodiment, chin strap 1694 is formed from a flexible
material such as rubber or fabric that is flexible or soft enough to be
comfortable to the
user while remaining strong enough to secure system 1600 on the user's head.
Chin
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strap 1694 has mating structures 1696 sized to mate with corresponding
attachment
points on rigid shell 1610 in order to couple chin strap 1694 to rigid shell
1610. In a
preferred embodiment, mating structures 1696 are configured to snap onto
corresponding snaps 1633 formed on side portions 1630 of rigid shell 1610.
Snaps
1633 are configured to provide a snug, secure connection to the mating
structures
1696 on chin strap 1694. Snaps 1633 may also be positioned within slots on
side
portions 1630 to allow chin strap 1694 to be adjusted to ensure the user's
comfort and
security.
Although the invention is illustrated and described herein with reference
to specific embodiments, the invention is not intended to be limited to the
details
shown. Rather, various modifications may be made in the details within the
scope and
range of equivalents of the claims and without departing from the invention.
In
particular, any of the features described herein with respect to one
embodiment may be
provided in any of the other embodiments.
