Note: Descriptions are shown in the official language in which they were submitted.
PROTECTIVE DEVICE FOR USE WITH HELMETS
Field
This application relates to headwear, particularly to protective headwear such
as
helmets.
Background
Helmets have been used for decades in sports to protect the head from injury
that
would otherwise occur as a result of an impact to the bare head. The typical
helmet is
composed of a rigid outer shell and internal padding. The rigid outer shell
acts to
withstand the contact of an impact force without fracture or damage. The
padding internal
to the outer shell acts to cushion the impact force and lengthen the duration
during which
the impact force is applied to the helmet and head so as to reduce the impact
force
magnitude to below the threshold for injury. A drawback of this design is that
the outer
shell does little to dissipate or absorb the impact force before it reaches
the internal
padding so that the impact force may still be sufficient to cause concussion,
contusion,
laceration or even a skull fracture. Further, when a helmet is exposed to a
high impact
force, the structure of the entire helmet may be compromised requiring
replacement of
the helmet.
There remains a need for a device that serves to absorb more of the impact
force
and to increase the duration of impact prior to the impact force reaching the
helmet and
the head beneath the helmet, thereby protecting both the helmet and the head
from
damage.
Summary
In one aspect, there is provided a protective device for use with a helmet,
the
protective device comprising a plurality of removable and replaceable
resilient deformable
sacrificial bubble structures adapted to be installed on a helmet to absorb an
impact force
when the impact force impacts the bubble structures.
In another aspect, there is provided a protective device for wearing over an
outer
surface of a helmet, the protective device comprising a helmet cover, the
helmet cover
comprising: a base layer capable of being fitted over the outer surface of the
helmet; a
plurality of individual pockets formed in the base layer; and, a plurality of
resiliently
deformable sacrificial elements in the plurality of pockets, the sacrificial
elements
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individually removable from and replaceable in the pockets, the sacrificial
elements
adapted to absorb an impact force when the impact force impacts the
sacrificial elements
In another aspect there is provided a helmet comprising the protective device
installed thereon.
Further features will be described or will become apparent in the course of
the
following detailed description. It should be understood that each feature
described herein
may be utilized in any combination with any one or more of the other described
features,
and that each feature does not necessarily rely on the presence of another
feature except
where evident to one of skill in the art.
Brief Description of the Drawings
For clearer understanding, preferred embodiments will now be described in
detail
by way of example, with reference to the accompanying drawings, in which:
Fig. 1 depicts a rear perspective view of a first embodiment of a protective
device
in the form of a helmet cover installed on a hockey style sporting helmet;
Fig. 2A depicts a front perspective view of the helmet cover of Fig. 1;
Fig. 2B depicts the helmet cover of Fig. 2A separated from the helmet;
Fig. 3 depicts the helmet cover of Fig. 2 with a base layer partially cut-away
to
show removable and replaceable resiliently deformable sacrificial elements
within pockets
of the helmet cover;
Fig. 4A depicts the helmet cover of Fig. 3 without the base layer to show
locations
of the sacrificial elements arranged on an outer surface of the helmet;
Fig. 4B depicts a rear perspective view of the helmet cover of Fig. 4A;
Fig. 5 depicts an exploded view of the helmet cover of Fig. 4A showing the
sacrificial elements separated from the helmet;
Fig. 6A depicts a front perspective view of a second embodiment of a
protective
device in the form of a helmet cover installed on a hockey style sporting
helmet, the
helmet cover having a sacrificial element being installed into a pocket
thereof;
Fig. 6B depicts a rear perspective of the helmet cover of Fig. 6A; and,
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Fig. 7 depicts a front perspective view of a third embodiment of a protective
device
installed on a hockey style sporting helmet.
Detailed Description
The present invention provides a protective device for use with helmets, which
is
installed on an outer surface of a helmet, for example a sporting helmet (e.g.
a hockey
helmet, a football helmet, etc.), a military helmet or a construction helmet.
More
particularly, the protective device is adapted to absorb an impact force and
to indicate the
impact force severity and location when the impact force has been realized on
the
protective device and the impact force exceeds a predetermined impact
threshold. Such
functionality is realized by bubble structures in the protective device.
In one embodiment, the protective device may be a single unit comprising a
plurality of individual bubble structures, the single unit fitted on to the
helmet. The single
unit may take the form of a helmet cover having a base layer, the base layer
holding the
protective device in place on an outer surface of the helmet. In another
embodiment, the
protective device may be a plurality of individual bubble structures attached
directly to the
helmet.
The bubble structures are preferably rigid. The bubble structures are
preferably
hollow or half hollow, more preferably hollow. The bubble structures are
preferably
resilient. The bubble structures are preferably sacrificial. The bubble
structures are
preferably individually removable and replaceable. The bubble structures may
comprise
removable and replaceable deformable sacrificial elements. For example, the
bubble
structures may comprise cushions, cells or the like. The bubble structures may
contain a
fluid, for example air at ambient, negative or positive pressure with respect
to
atmospheric pressure.
The protective device absorbs the impact force of any impact on the outer
surface
of the underlying helmet by ensuring that the impact contacts with one or a
plurality of the
bubble structures rather than the helmet itself. The bubble structures may
provide
complete or partial coverage, preferably complete coverage, of the outer
surface of the
helmet. Bubble structures having selected deformation properties may be
strategically
placed at selected locations on the helmet based on susceptibility to injury
to a wearer's
head at those locations. Optimal locations for the bubble structures will
depend on the
type of helmet and type of activity.
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The bubble structures are configured to deform, crush or rupture when impacted
with sufficient force. The bubble structures may deform when the impact force
is less than
a prescribed lower force threshold and have sufficient resiliency to rebound
to original
shape without damage after the impact force is removed. The bubble structures
may
crush permanently when the impact force is above the lower force threshold but
below a
higher force threshold. The bubble structures may rupture when the impact
force is above
the higher force threshold. The act of deforming, crushing or rupturing the
bubble
structures absorbs a portion or all of the impact force before the impact
force reaches the
underlying helmet. The act of rupturing the bubble structure may result in the
release or
intake of fluid (e.g. air) depending on the pressure of the fluid in the
bubble structure and
the type of bubble structure employed. The resulting release or intake of
fluid absorbs a
further portion of the impact force before the impact force reaches the
underlying helmet.
Reduction in impact forces can be expressed as an average energy absorption of
the
bubble structure. During impact, the bubble structure dissipates energy to the
surrounding
air so that energy is not transferred to the helmet under the protective
device, and in turn
that energy does not reach a person's head in the helmet. Preferably, the
bubble
structure provides an average energy absorption of 20% or more of the total
energy of the
impact.
Further, the crush or rupture of one or a plurality of the bubble structures
serves to
indicate the location and severity of the impact force. The bubble structures
that have
been crushed or ruptured are easily removed from the protective device to be
replaced
with intact bubble structures. The protective device can thereby be used
during sport or
other activities to withstand multiple impacts to the head. Further, the
protective device
can be removed from the helmet and installed on another helmet as the need
arises to
afford additional protection to the other helmet.
In one embodiment, the protective device is a helmet cover having a base layer
and a plurality of structures in the base layer. The bubble structures may be
contained in
a plurality of pockets formed into the base layer of the helmet cover and held
in place on
the outer surface of the helmet by the base layer. The base layer and/or
pockets of the
helmet cover preferably comprises a flexible material, for example a flexible
fabric. The
flexible material may be woven or non-woven. A non-woven material may be, for
example, a foam. Flexible materials include, for example, materials that have
elastic
properties. Some examples of suitable materials include polychloroprene rubber
(e.g.
Neoprene TM), spandex, cotton, cotton-spandex blends, nylon, cotton-nylon
blends and
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the like. The base layer conforms to the outer surface of the helmet when the
base layer
comprises a flexible material.
Within the base layer, individual pockets are formed configured to contain the
bubble structures. The base layer and/or pockets may comprise a stretchable
material
that can be stretched to accommodate different shapes and sizes of bubble
structures
placed within the individual pockets. The pockets may be formed by any
suitable method,
for example by sewing or welding the pockets into the base layer. Each pocket
preferably
has an opening, for example a seam, either on a surface of the base layer
proximal to the
outer surface of the helmet or on a surface of the base layer distal to the
outer surface of
.. the helmet. The opening may be openable and closable with a closure such as
a hook
and loop strip (e.g. Velcro TM), a snap fastener, a button, a zipper, a
drawstring, a magnet
or the like. However, the individual pockets may have no closure, in which
case the
bubble structure may be held within the pocket via the tightness of the walls
of the pocket.
The opening in each pocket allows the bubble structure to be removed after the
bubble
structure has been crushed or ruptured so that the bubble structure can be
replaced with
a new, intact bubble structure. The pockets may have different shapes and/or
sizes to
prevent installation of an incorrect bubble structure at a given location on
the helmet
cover.
The bubble structures preferably comprise a material that can be formed, for
example molded (e.g. blow molded, injection molded, rotational molded or
vacuum
thermoformed), into a desired shape. Complete hollow structures may be formed
by blow
molding or rotational molding. Half hollow structures may be formed with
injection molding
and vacuum thermoforming. Half hollow structures may be assembled into
complete
hollow structures by mechanically fastening two half hollow pieces together,
for example
.. by welding. Half hollow structures may be used without assembly into
complete hollow
structures but half hollow structures used in this manner may not have a fluid
retention
capability. Preferably, the material is formed into complete hollow structures
that form the
bubble structures. The bubble structures may be filled with a fluid, for
example air. The
fluid may be at ambient pressure, negative pressure or positive pressure in
the bubble
.. structure with respect to air pressure outside the bubble structure. The
fluid is preferably
at ambient pressure. The fluid is preferably air.
Preferably, the bubble structures comprise a plastic material, particularly a
thermoplastic material, for example high density polyethylene (HDPE), medium
density
polyethylene (MDPE), low density polyethylene (LDPE), polypropylene (PP),
polyethylene
terephthalate (PET) and the like. Polypropylene is stiffer than high density
polyethylene,
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which his stiffer than low density polyethylene. Average energy absorption of
bubble
structures made from low density polyethylene is about 32%, but the lesser
stiffness may
result in opposite walls of the bubble structure touching ("bottoming out")
during an
impact. Average energy absorption of bubble structures made from high density
polyethylene is about 25%, which is lower than low density polyethylene but
HDPE is
stiffer mitigating against bottoming out. However, HDPE may exhibit wear after
multiple
impact events. Average energy absorption of bubble structures made from
polypropylene
is about 23%, which is lower than LDPE, but the stiffness of polypropylene
provides
greater resiliency to multiple impacts than HDPE.
The bubble structures are preferably shaped as prisms having rounded corners
(i.e. rounded prism shapes). Thus, the edges and vertices of walls of the
bubble
structures are rounded. The bubble structures have concave proximal surfaces
that are
proximate the outer surface of the helmet when the helmet cover is installed
on the
helmet. The bubble structures may also have convex distal surfaces that are
farther away
from the outer surface of the helmet when the helmet cover is installed on the
helmet.
The concave proximal surfaces of the bubble structure are complementary to and
follow
the outer surface of the underlying prior art helmet. The convex distal
surfaces of the
bubble structures may also be complementary to and follow the contour of the
outer
surface of the helmet. Lateral surfaces of the bubble structures are
preferably generally
straight and planar in the form of a rectangle. The lateral surfaces of
adjacent bubble
structures are preferably parallel with one another. The material that
comprises an
individual bubble structure is preferably continuous throughout the bubble
structure
having no joints therein. The distal and lateral surfaces may contain
corrugations to stiffen
the bubble structure without added material or wall thickness. The bubble
structures may
contain vent holes to permit fluid (e.g. air) to escape during deformation
during an impact.
One or more of the size of the vent hole, material properties and physical
design features
of the bubble structures may be selected to provide differing deformation
properties to the
bubble structures. The bubble structures may be color-coded to facilitate
identification of
the type of bubble structure, for example which bubble structures have mild,
medium or
strong deformation properties. Bubble structures having differing deformation
properties
may be placed at selected locations on the base layer to provide different
impact
protection properties at those locations.
With reference to Fig. 1, Fig. 2A, Fig. 2B, Fig. 3, Fig. 4 and Fig. 5, a
protective
helmet cover 10 is worn on an outer surface 13 of a helmet 12, for example a
hockey
sporting helmet. The helmet cover 10 comprises of a flexible fabric base layer
11 on
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which individual pockets 14 are installed, for example by sewing. The base
layer 11 fits
tightly over the outer surface 13 of the helmet 12. Each of the pockets 14
contain a rigid
hollow air-filled cushion 16. The helmet cover 10 thereby holds in place a
plurality of the
cushions 16 over the outer surface 13 if the helmet 12. The cushions 16 may be
inserted
into the pockets 14 though open seams 15 (only one labeled) in the pockets 14.
The open
seams 15 may be openable and closable, if desired, with closing structures,
for example
hook and loop strips, buttons, elasticized bands, snap fasteners, zippers,
magnets and
the like.
As shown in Fig. 1 to Fig. 5, the cushions 16 may be arranged with lateral
walls 17
(not all labeled) of each cushion configured to be substantially parallel to
lateral walls 17
of adjacent cushions, the adjacent lateral walls 17 separated by narrow gaps
18 (only one
labeled). The arrangement and configuration of cushions 16 is designed to give
substantially complete coverage of the outer surface 13 of the underlying
helmet 12. In
other embodiments, the cushions may be arranged in different configurations
while still
maintaining coverage of the outer surface of the helmet.
Fig. 6A and Fig. 6B depict a second embodiment of a protective helmet cover
20,
the helmet cover 20 having rigid hollow air-filled thermoplastic cushions 26
(only one
labeled) installed into spandex pockets 24 sewn into a base layer 21 of
spandex. The air-
filled thermoplastic cushions 26 contain air at ambient pressure. The cushions
26 are
contoured and have side-walls 27 and grooves 29 formed therein to provide
stiffness to
the cushions 26 without adding to the weight or wall thickness of the cushions
26. The
cushions 26 are insertable into the pockets 24 through open seams 25 (only one
labeled)
in the pockets 24. The cushions 26 are somewhat larger than the pockets 24 so
that once
the cushions 26 are inserted in the pockets 24 the spandex tightens around the
cushions
26 to secure the cushions 26 in the pockets 24. The pockets 24 are spaced-
apart on the
base layer 21 to provide narrow gaps 28 (only two labeled) between the
cushions 26. In
use, the air-filled thermoplastic cushions 26 deform under the force of an
impact. If the
impact force is less than a first force threshold, the deformed cushion
returns to original
shape once the force is removed. If the impact force is less than a second
force threshold
but more than the first force threshold, the cushions 26 are crushed, and must
be
removed and replaced. If the impact force is more than the second force
threshold, the
cushions 26 are further ruptured releasing the air inside thereby absorbing at
least a
portion of the impact force.
Fig. 7 depicts a third embodiment of a protective device 40 installed on an
outer
surface 41 of a helmet 42, for example a hockey sporting helmet. The
protective device
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40 comprises a plurality of air-filled cells 46 formed directly on to the
outer surface 41 of
the helmet 42. The air-filled cells 46 contain air at ambient pressure. Each
cell 46
comprises a depression 44 integrally molded into the outer surface 41 of the
helmet 42
and a rigid perimeter wall 48 attached to the outer surface 41, for example by
welding,
and extending from the outer surface 41. Each cell 46 further comprises a
flexible
thermoplastic cover plate 43 having a perimeter that generally follows a
contour of the
perimeter wall 48. The cover plate 43 is sized to be seated on the perimeter
wall 48 or on
a perimetrical lip that follows the contour of the perimeter wall 48. The
cover plate 43 is
removably secured and possibly sealed on the perimeter wall 48 by a rigid
securing ring
45, the securing ring 45 having a perimetrical shape that generally follows
the contour of
the perimeter wall 48. The securing ring 45 may be secured to the perimeter
wall 48 by
screws or bolts 51 through first threaded apertures 52 of the securing ring
45, which align
with second threaded apertures 53 on the perimeter wall 48 when the securing
ring 45 is
properly fitted on the perimeter wall 48. The cover plate 43 is held securely
between the
securing ring 45 and the perimeter wall 48 when installed in the cell 46. The
cover plate
43 may be flat or convex depending on the location on the helmet 42 at which
the cell 46
is situated. When a cover plate 43 is broken due to an impact force, the
securing ring 45
may be removed by removing the screws or bolts 51 and the broken cover plate
may be
replaced with an intact cover plate 43.
The novel features will become apparent to those of skill in the art upon
examination of the description. It should be understood, however, that the
scope of the
claims should not be limited by the embodiments but should be given the
broadest
interpretation consistent with the wording of the claims and the specification
as a whole.
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