Note: Descriptions are shown in the official language in which they were submitted.
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PROTECTIVE HELMET
TECHNICAL FIELD
[0001] The present invention relates to devices and methods for
optimizing a protective helmet
or other item of protective clothing with various impact and/or protection
zones, some or all of which
incorporate flexible, pliable and/or "softer" protective features that, in
various embodiments, could be
particularized to a specific sport, player-position and/or the individual
behavior of a specific player.
More specifically, the present invention relates to devices and methods that
can be utilized to protect
an athlete or other individual from a variety of incidental impacts (i.e.,
hitting another player and/or
having their head strike the ground or goal post) as well as single and/or
repetitive head impacts from
relatively high speed, "lighter" objects during sports such as footballs,
lacrosse balls, softballs, soccer
balls, basketballs, baseballs, field hockey pucks, rugby balls, jai alai balls
and/or water polo balls.
BACKGROUND OF THE INVENTION
[0002] Many modern organized sports employ substantial "hard and/or
flexible shell" helmets
that are designed to provide players with significant head protection from
intentional and/or
unintentional impacts, including substantial impacts having a significant
potential to cause traumatic
brain injuries (TB!). However, many shell helmet designs are fairly bulky and
heavy, and they often limit
a player's visibility and "field awareness" when worn. Moreover, research
suggests that the protection
provided by shell helmets may result in a higher incidence of hits involving
the player's head, in that
the shell helmet may cause the player to develop a feeling of
"invulnerability," possibly leading the
player to "lead with their helmet" during collisions. Furthermore, the use of
hard shell helmets may be
limited in some sports (e.g., soccer, rugby and women's lacrosse) due to the
requirements and/or
traditions within the game.
[0003] Soccer (also called "football" outside of the United States of
America) is one of the
world's most popular sports. Like many athletic activities, soccer involves
some risk of injury, including
head injury. While intentional contact between soccer players is highly
discouraged, head injuries in
soccer can include head collisions with another player's head, elbow, knee, or
foot, as well as injuries
when the head collides into a goal post, the ground or some other object.
[0004] A less well-known cause of head injury in soccer and other sports
is the use of the head
by a player to redirect a soccer ball in a desired direction at a desired
speed, in what is typically called a
"header." Many studies have shown that "heading" a soccer ball (or similar
repetitive impacts) can
cause minor cumulative brain damage. Many soccer players who repeatedly headed
the ball during
their careers have been found to have chronic changes on their
electroencephalograms (EEGs), in many
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ways similar to the changes found in amateur boxers. These players were found
to have chronic mild
to severe deficits in attention, concentration, memory, and judgement. More
importantly, children,
who have had significantly less exposure to heading a soccer ball that their
professional counterparts
(but who do play soccer on a frequent basis) have been found to have greater
changes in their EEGs.
[0005] While hard shell-type helmets are conventionally used in most
sports which involve a
risk of head injury from one or more major impact events, such as American
football, baseball, ice
hockey, lacrosse, cycling, skiing, snowboarding, kayaking, equestrian sports,
and rock climbing, such
hard shell helmets can often interfere with the "play" and/or enjoyment of a
sport, such as seriously
interfering with a soccer player's ability to "head" a ball - thus interfering
with the very nature of the
sport of soccer. Thus, conventional helmets are not used in soccer, even
though there is a significant
risk of head injury.
BRIEF SUMMARY OF THE INVENTION
[0006] The present invention includes the realization of a need for a
lightweight, flexible, form-
fitting protective helmet for various occupations and participants of sports
and sporting activities
where a more substantial and/or heavier rigid or shell-type helmet may be
undesirable for a variety of
reasons. More specifically, the soft-shell helmet or soft helmet should
provide protection for both
"ball-to-head" related impacts and "non-ball" related impacts (e.g., head-to-
head, elbow-to-head,
head-to-ground, etc.). The protective helmet or soft-shell helmet may comprise
a partial head
coverage or full head coverage protection.
[0007] In at least one exemplary embodiment, a "soft" shell helmet can
include a protective
headband. The protective headband can protect at least a portion of the head.
The protective
headband may comprise a tubular or generally cylindrical shape and
configuration, which desirably fits
around an upper portion of the wearer's head (i.e., across the forehead and
above a portion of the
ears). The headband may comprise at least one or more padded regions and at
least one boot layer.
The at least one boot layer may comprise one single material layer or two or
more material layers. In
one preferred embodiment, the at least one boot layer may comprise at least
one first material, at
least one second material, and at least one foam material and/or layer, the at
least one foam material
and/or layer being affixed to the at least one first and at least one second
material. The at least one
first or at least one second material may be a two- or four-way stretch
fabric, where the top and
bottom covering may be the same material or the at least one top and bottom
covering may be
different materials. The at least one or more padded regions comprising one
more individual impact
pads, which can be separated by one or more stretchable regions. In various
embodiments, the
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stretchable regions can comprise one or more layers of elastic material or
"two- or four-way stretch
fabric," which can allow the helmet to be expanded and/or contracted to
accommodate heads of
differing shapes, sizes and/or configurations, as well as to accommodate
different wearing positions
and/or styles by the player. Various embodiments can further include lower
portions for extending
along the sides, face and/or jaws of the wearer, as well as an optional peak
or domed portion for
protecting the top of the wearer's head. In various embodiments, the padded
regions may protect the
forehead, temples, and the occipital bone in the back of the wearer's head.
[0008] In one exemplary embodiment, a soft-shell helmet may comprise a
full-coverage or full-
face soft-shell helmet. The full-coverage helmet may cover the entire head,
with a rear that covers the
base of the skull, and a protective section that may cover the front of the
chin and temples. Such full
coverage helmets desirably have an open cutout to allow access to the face.
[0009] The full-coverage soft-shell helmet can comprise at least one of a
boot layer or liner, at
least one impact pad, at least one optional ear cover (which may comprise a
removable and/or
replaceable separate ear cover), a chinstrap, and/or any combination thereof.
The at least one boot
layer may comprise one single material or two or more materials. The at least
one boot layer may
further comprise an impact mitigation layer. In one preferred embodiment, the
at least one boot layer
may comprise at least one first material, a second material, and a foam layer
material, the foam layer
being affixed to the first and second material and disposed between the first
and second material. The
at least one ear cover and/or the chinstrap may be removably coupled to the
soft-shell full-coverage
helmet. The at least one or more individual impact mitigation pads may be
directly affixed to the boot
layer or liner. The impact mitigation pads may be desirably positioned on
different regions of the head,
including the frontal section, top or ridge section, lower back, mid-back,
left side and front side,
temples, jaw region and/or any combination thereof. The at least one or more
individual impact pads
may comprise at least one impact structure that can be affixed to the boot
layer in desired regional
locations to enhance impact protection. The at least one or more individual
impact pads may further
comprise a foam layer.
[00010] In various embodiments, the soft-shell helmet may optionally not
incorporate an ear
cover and/or may comprise a perforated portion of the helmet and/or may
comprise a material
capable of reasonable levels of sound transmission therethrough.
[00011] In another exemplary embodiment, the at least one or more
individual impact pads may
further comprise at least one impact structure, at least one first layer and
at least one second layer.
The at least one first layer or the at least one second layer may include a
foam layer, polycarbonate
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layer, a hotmelt layer, a 2-way stretch material, a 4-way stretch material,
Lycra, Ducksan Power Net,
Neoprene, and/or any combination thereof. The polycarbonate layer can be thin,
flexible, yet
substantially rigid to assist with absorption of the forces and reduce
wear/tear. The foam layer can
include polymeric foams, quantum foam, polyethylene foam, polyurethane foam
(PU foam rubber),
XPS foam, polystyrene, phenolic, memory foam (traditional, open cell, or gel),
impact absorbing foam,
compression foam, latex rubber foam, convoluted foam ("egg create foam"), EVA
foam, VN 600 foam,
EvIon foam, Ariaprene or Ariaprene-like material, impact hardening foam,
and/or any combination
thereof. The at least one foam layer may have an open-cell structure or closed-
cell structure. The
foam layer can be further tailored to obtain specific characteristics, such as
anti-static, breathable,
conductive, hydrophilic, high-tensile, high-tear, controlled elongation,
and/or any combination thereof.
[00012] In another exemplary embodiment, the at least one or more
individual impact pads may
further comprise at least one impact structure assembly, at least one first
layer and at least one second
layer. Alternatively, the at least one or more individual impact pads may
further comprise at least one
impact structure assembly, at least one foam layer, at least one first layer
and at least one second
layer. The impact structure assembly may comprise a two-piece assembly that
comprises an impact
mitigation structure and a first layer. The first layer may comprise a recess
forming a pocket and a
flange, the pocket may be shaped and configured to receive the impact
mitigation structure, the impact
mitigation structure disposed within the pocket. The at least one second layer
may be affixed to the at
least one first layer, impact mitigation structure, at least one second layer,
and/or any combination
thereof. Alternatively, the impact structure assembly may comprise a one-piece
assembly that
integrates the impact mitigation structure within the first layer. The one-
piece impact mitigation
structure assembly is comprised of a first layer and an impact mitigation
structure that may be
thermoformed, injection molded, 3D printed, casted and/or die cut as a one-
piece construct.
[00013] The at least one first layer and/or the at least one second layer
may comprise a single
layer or multiple layers. Each of the at least one first layer and/or the each
of the at least one second
layer may comprise a 2-way stretch material, a 4-way stretch material, a foam
layer, a polycarbonate
layer, a hotmelt layer, a boot layer, Lycra, Ducksan and/or any combination
thereof. The polycarbonate
layer can be thin, flexible, yet substantially rigid to assist with absorption
of the forces and reduce
wear/tear. The foam layer can include polymeric foams, quantum foam,
polyethylene foam,
polyurethane foam (PU foam rubber), XPS foam, polystyrene, phenolic, memory
foam (traditional,
open cell, or gel), impact absorbing foam, latex rubber foam, convoluted foam
("egg create foam"), EVA
foam, VN600 foam, EvIon foam, Ariaprene or Ariaprene-like material, impact
hardening foam,
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compression and/or any combination thereof. The at least one foam layer may
have an open-cell
structure or closed-cell structure.
[00014] In one exemplary embodiment, the at least one or more individual
impact pads may be
encapsulated to form pockets, where the pockets can be affixed to the boot
layer. The at least one or
more individual impact pads may comprise at least one impact structure and/or
at least one impact
structure assembly, at least one first layer, at least one second layer, and
at least one top covering or at
least one bottom covering. Alternatively, the at least one or more pocketed
individual impact pads
may comprise an impact mitigation structure and/or at least one impact
mitigation structure assembly,
and a least one top covering. The at least one first layer or the at least one
second layer may include a
2-way stretch material, a 4-way stretch material, a foam layer, polycarbonate
layer, a hotmelt layer,
boot layer and/or any combination thereof. The at least one top or at least
one bottom covering may
be a two- or four-way stretch fabric, where the top and bottom covering may be
the same material or
the at least one top and bottom covering may be different materials. The
impact mitigation structure
may be "free-floating" and/or fixed within the at least one top covering
and/or at least one bottom
covering, or permanently secured within the at least one top and/or bottom
covering. The
polycarbonate layer can be thin, flexible, yet substantially rigid to assist
with absorption of the forces
and reduce wear/tear. The foam layer can include polymeric foams, quantum
foam, polyethylene
foam, polyurethane foam (PU foam rubber), XPS foam, polystyrene, phenolic,
memory foam
(traditional, open cell, or gel), impact absorbing foam, latex rubber foam,
convoluted foam ("egg create
foam"), EVA foam, VN600 foam, EvIon foam, Ariaprene or Ariaprene-like
material, impact hardening
foam, compression foam, and/or any combination thereof. The at least one foam
layer may have an
open-cell structure or closed-cell structure. The foam layer can be further
tailored to obtain specific
characteristics, such as anti-static, breathable, conductive, hydrophilic,
high-tensile, high-tear,
controlled elongation, and/or any combination thereof.
[00015] In various embodiments, the one or more impact pad section(s) can
comprise at least
one impact structure, the at least one impact structure can comprise at least
a portion of filaments, a
portion of auxetic structures, a portion of zigzag structures, a portion of
herringbone structures, and/or
laterally supported filaments and/or wall structures. Such impact mitigation
structures may include
polygonal structures and/or thin, longitudinally extending members that may be
shaped and
configured to deform non-linearly in response to an impact force, auxetic
structures, re-entrant
structures, TPU cones, impact foam, and/or any combination thereof. In various
instances, a non-linear
deformation behavior of one or more of these structures is expected to provide
improved protection
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against high-impact forces and/or oblique forces, as well as afford a
significant level of durability,
elasticity and/or flexibility to the impact pad section(s). In various
embodiment, the impact pad
section(s) can be deformable and/or stretchable, which can include
deformability in a variety of
directions, including along the cephalad/caudal, medial/lateral and/or
anterior/posterior axes of the
helmet and/or the wearer, as well as complex combinations thereof.
[00016] In various embodiments, the one or more impact pad sections could
comprise auxetic
structures and/or could comprise re-entrant shaped structures, such as bowtie
shapes, and/or could
comprise a series of repeating geometric shapes or undulating structures, such
as T-shaped or chevron
shapes, or various combinations thereof.
[00017] In various embodiments, a soft helmet design could be designed
and/or tailored to
accommodate various types and/or locations of forces, including factors or a
combination of two or
more factors in a sport-specific and/or position-specific manner, which could
include impact protection
features designed to protect against one or more specific locations and/or
types of locations and/or
degrees of impact or other forces, including (but not limited to) source of
impact, angle of impact,
player activity type, play type, player position, location of impact, angle of
impact, severity of impact,
and/or frequency of impacts.
[00018] In one embodiment, an impact mitigation structure comprises a
plurality of spaced
apart elongated walls, each of the plurality of elongated walls having a wall
height and a undulated
pattern, each of the plurality of elongated walls having a cross-sectional
shape, the cross-sectional
shape including a first lower portion and a second upper portion, the first
lower portion comprising a
base having a cross-sectional base width and a base height, the second upper
portion comprising an
upwardly extending longitudinal member, the upwardly extending longitudinal
member extending
generally perpendicular from the base and having a cross-sectional
longitudinal member width and a
longitudinal member height, the base width is greater than the longitudinal
width and the base height
is less than the longitudinal member height; and at least one support member,
the at least one support
member extending perpendicular from at least a portion of a length of the
plurality of spaced apart
elongated walls.
[00019] In one embodiment, an impact mitigation pad comprises a base
material layer, the base
material layer having a first surface and a second surface, a recess disposed
onto a first surface
extending towards the second surface; and an impact mitigation structure, the
impact mitigation
structure comprising a plurality of spaced apart elongated walls, the
plurality of spaced apart walls
disposed within the recess, the recess having a recess height, each of the
plurality of elongated walls
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having an elongated wall height, an elongated wall width and a undulated
pattern, each of the plurality
of elongated walls having a cross-sectional shape.
[00020] In one embodiment, the protective helmet comprises a liner, the
liner having an
external surface and an internal surface; and a plurality of impact pads, at
least a portion of the
plurality of impact pads comprising base material layer, an impact mitigation
structure, a first material
layer and a second material layer, the base material layer having a first
surface and a second surface, a
recess disposed onto a first surface extending towards the second surface, the
impact mitigation
structure comprising a plurality of spaced apart elongated walls, the
plurality of spaced apart walls
disposed within the recess, the recess having a recess height, each of the
plurality of elongated walls
having an elongated wall height, an elongated wall width and a undulated
pattern, each of the plurality
of elongated walls having a cross-sectional shape, the plurality of impact
pads being coupled to the
liner external surface.
[00021] While the various optimized soft-shell helmet components and/or
designs provided
herein are depicted with respect to soccer and/or related sports, it should be
understood that the
various devices, methods and/or components may be suitable for use in
protecting players in various
other athletic sports, as well as law enforcement, military and/or informal
training session uses. For
example, the embodiments of the present invention may be suitable for use by
individuals engaged in
athletic activities such as football, two hand touch football, flag football,
softball, dodge ball, baseball,
bowling, boxing, cricket, cycling, motorcycling, golf, hockey, lacrosse,
soccer, rowing, rugby, running,
skating, skateboarding, skiing, snowboarding, surfing, swimming, table tennis,
tennis, or volleyball,
water polo, wrestling, wakeboarding and/or during training sessions related
thereto.
[00022] Described herein are many specific embodiments, but these should
not be construed as
limitations on the scope of any inventions or of what may be claimed, but
rather as descriptions of
factors specific to various implementations of the present inventions. Certain
factors described herein
in the context of separate implementations can also be implemented in a single
implementation.
Conversely, various factors described in the context of a single
implementation can also be
implemented in multiple implementations separately or in any suitable sub
combination. Furthermore,
the factors as described above may be recited as acting in certain
combinations and even initially
claimed as such, one or more factors from a claimed combination can in some
cases be excised from
the combination, and the claimed combination may be directed to a sub
combination or variation of a
sub combination.
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DETAILED DESCRIPTION OF DRAWINGS
[00023] FIG. 1 depicts an isometric view of one embodiment of a soft-shell
helmet;
[00024] FIG. 2A depicts a side view of an alternate embodiment of a soft-
shell helmet;
[00025] FIG. 2B depicts a front view of one embodiment of a boot layer or
liner;
[00026] FIG. 3A depicts a side view of the soft-shell helmet in FIG. 2A;
[00027] FIG. 3B depicts a front view of one embodiment of one or more
impact mitigation
structures;
[00028] FIGS. 4A-46 depicts a top and side view of an alternate embodiment
of one or more
impact mitigation structures;
[00029] FIG. 5 depicts a side and isometric view of an impact mitigation
structure that may be
encapsulated in a soft shell helmet;
[00030] FIG. 6 depicts a top view of an alternate embodiment of one or
more impact mitigation
structures;
[00031] FIGS. 7A-76 depict exploded views of different embodiments of a
boot layer or liner;
[00032] FIGS. 7C-7D depict cross-sectional views of one embodiment of a
boot layer or liner;
[00033] FIGS. 8A-8C illustrate top views of different embodiments of the
one or more impact
mitigation structure configurations;
[00034] FIGS. 9A-9E illustrate one embodiment of a method to manufacture a
boot layer or
liner;
[00035] FIGS. 10A-10C depict cross-sectional views of one or more impact
mitigation pads or
one or more impact mitigation structures coupled to a boot layer or liner;
[00036] FIGS. 11A-11G illustrate one embodiment of a method to manufacture
one or more
impact mitigation pads;
[00037] FIGS. 12A-12C illustrate one embodiment of a method to couple the
one or more impact
mitigation pads to a boot layer or liner;
[00038] FIGS. 13A-13I3 depict a side and front view of the soft-shell
helmet of FIG. 2A;
[00039] FIG. 13C depicts a front view of one alternative embodiment of a
covered soft-shell
helmet;
[00040] FIG. 14 depicts one embodiment of an assembly of a soft-shell
helmet;
[00041] FIGS. 15A-15C depicts an alternate embodiment of a method to
couple or affix the one
or more impact mitigation pads to a boot layer or liner;
[00042] FIGS. 16A-16I3 depicts different embodiments of one or more impact
mitigation pads;
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[00043] FIGS. 17A-17C illustrates one embodiment of a boot layer or liner
construction;
[00044] FIG. 18 depicts a front view of one embodiment of a headband;
[00045] FIGS. 19A-196 depicts a front view of one embodiment of a soft
shell helmet with ear
protection;
[00046] FIG. 20 depicts an isometric view of an alternate embodiment of an
impact structure;
[00047] FIG. 21 depicts a top view of one embodiment of an undulated wall
impact structures;
[00048] FIGS. 22A-22C depicts various views of an alternate embodiment of
a soft-shell helmet;
[00049]
FIGS. 23A-236 depicts one embodiment of a front impact pad assembly and/or a
rear impact pad
assembly to form a soft-shell helmet;
[00050] FIGS. 24 depicts one embodiment of a front impact pad assembly to
form a soft-shell
helmet;
[00051] FIGS. 25A-256 depicts a top and bottom view of one embodiment of
one or more
impact mitigation pads;
[00052] FIGS. 26A-266 depicts a front and isometric view of an alternate
embodiment of one or
more impact mitigation pads;
[00053] FIGS. 27A-276 depicts an exploded view of an alternate embodiment
of one or more
impact mitigation pads;
[00054] FIGS. 28A-286 depicts a side view of the one or more impact
mitigation pads of FIGS.
27A-276 coupled to a base layer or liner;
[00055] FIGS. 29A-29F depict one embodiment of a method to manufacture a
front impact pad
assembly to form a soft-shell helmet;
[00056] FIGS. 30A-30C depict one embodiment of a method to manufacture a
back impact pad
assembly to form a soft-shell helmet;
[00057] FIGS. 31A-31C depict one embodiment of a method to couple the
front impact pad
assembly with the back impact pad assembly to form a soft-shell helmet;
[00058] FIGS. 32A-326 depict a front and side view of an alternate
embodiment of a headband;
[00059] FIGS. 33A-33D depict different views of one embodiment of a
headband construction;
[00060] FIGS. 34A-34C depicts various views of one embodiment of a
headband size and
configuration on a head of wearer;
[00061] FIGS. 35A-35C depicts one embodiment of a method to manufacture
the one or more
impact mitigation structures for a headband;
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[00062] FIGS. 36A-36C depicts different views of an alternate embodiment
of a headband with
headband skin;
[00063] FIGS. 37A-37C depicts different views of an alternate embodiment
of a headband;
[00064] FIG. 37D depicts an exploded view of a portion of the headband of
FIGS. 37A-37C; and
[00065] FIGS. 38A-38G depicts various views of an alternate embodiment of
a soft-shell helmet.
DETAILED DESCRIPTION OF THE INVENTION
[00066] SOFT SHELL HELMETS
[00067] The term "soft helmet" or "soft shell" should not be limited to
helmet designs that
solely incorporate only soft or flexible components, but could also include
helmets or other protective
clothing designs that may incorporate harder and/or relatively rigid, shell or
plate components or similar
features, including the incorporation of flexible or sliding plates that can
accommodate stretching
and/or flexing of the overlying/underlying helmet structure(s).
[00068] In various embodiments, a soft helmet can comprise a headband,
head wrap, cap
and/or full coverage helmet having one or more impact mitigating structures
disposed thereon, such as
shown in Figure 1, Figure 2, Figure 13A, and/or Figure 18. The soft helmet may
comprise at least one of
a breathable and/or sweat wicking layer, an impact mitigating structure layer,
a foam layer, a boot layer
and/or any combination(s) thereof. Figure 1 and 19A-19I3 depicts an isometric
view of one
embodiment of a soft helmet design. The soft helmet 10 comprises a boot layer
or liner 30 and one or
more impact mitigation pads 20. The soft helmet 10 may further comprise ear
protection 35 or a chin
strap (not shown). The impact mitigation pads 20 may be desirably affixed to
an external surface of the
boot layer or liner 30 and positioned on different regions of the head,
including the frontal section, top
or ridge section, lower back, mid-back, left side, right side and front side,
temples, jaw region and/or any
combination thereof. The impact mitigation pads 20 may comprise impact
mitigation structures. The
impact mitigating structures may comprise deforming filament and/or laterally
supported filaments,
and/or lateral wall-based structures, including the employment of repeating
geometric patterns,
undulating structures, and/or auxetic/non-auxetic impact mitigating
structures. Figures 2A-26 and 3A-
36 depict another exemplary embodiment of a soft helmet 40. The soft helmet
system 40 comprising a
liner or boot layer 50 and an impact mitigation layer 60. The impact
mitigation layer comprises one or
more impact mitigation pads or impact mitigation structures that can be
affixed to an external surface of
the liner or boot layer 50. The impact mitigating structures comprising a
portion of filaments, laterally
supported filaments, undulating structures or repeating geometric patterns,
and/or auxetic wall
structures.
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[00069]
Figures 3A-36 depicts one embodiment of an impact mitigation layer 60. The
impact
mitigation layer 60 can comprise one or more impact mitigation structures 90.
The impact mitigation
structures 90 can include "auxetic" structures, a plurality of interconnected
members forming an array
of reentrant shapes positioned on the flexible head layer. Each of the
reentrant shapes may be
connected to the adjacent reentrant shape by at least one shared wall. In one
specific embodiment,
impact mitigation structures 90 may comprise a plurality of interconnected
reentrant structures forming
an array, the array comprises a first reentrant shape and a second reentrant
shape, the second
reentrant shape is connected perpendicular to the first reentrant shape. Each
of the first or second
reentrant shape having a length, the length provides for an ideal buckling
structure, the buckling is a
sudden lateral defection away from a longitudinal axis. The term "auxetic"
generally refers to a material
or structure that has a negative Poisson ratio, when stretched, auxetic
materials or structures become
thicker (as opposed to thinner) in a direction perpendicular to the applied
force. The employment of
such auxetic structures can result in a protective device capable of high
energy absorption and fracture
resistance. In particular, when a force is applied to the auxetic material or
structure, the impact may
cause it to expand (or contract) in one direction, resulting in associated
expansion (or contraction) in a
perpendicular direction. It should be recognized by those skilled in the art
that the auxetic structures
shown in FIG. 2A-26 and 3A-36 may include a wide variety of differently shaped
segments or other
structural members, as well as combinations of repeating and/or different
shaped voids. The one or
more impact mitigation structures 90 can be injection molded, where the
injection molded process
allows the one or more impact mitigation structures 90 to be manufactured
flat, and flexible. The one
or more impact mitigation structures 90 may be flexed to affix to the head
boot or liner 50 to conform
to the complex curvature of the head. Alternatively, the one or more impact
mitigation structures 90
may be covered by a fabric (not shown).
[00070]
Accordingly, the boot layer or liner 50 may be constructed from a single,
continuous
template or using two or more templates. As shown in Figure 2B, the boot layer
or liner 50 may
comprise two or more templates 80, 90. The two or more templates 80, 90 may be
coupled together to
form the boot layer or liner 50 that can be form fitting and substantially
conforms to a wearer's head.
The boot layer or liner 50 may comprise an ear aperture 70, where the ear
aperture 70 is sized and
configured to fit a wearer's ear and/or ear protection. Furthermore, the boot
layer or liner 50 may
comprise one or more layers. More specifically, the boot layer or liner 50 may
comprise at least a first
layer, a second layer. The first or second layer may comprise a foam layer
(e.g., EVA), a 4-way stretch
material, or a 2-way stretch material. The foam layer can include polymeric
foams, quantum foam,
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polyethylene foam, polyurethane foam (PU foam rubber), XPS foam, polystyrene,
phenolic, memory
foam (traditional, open cell, or gel), impact absorbing foam, compression
foam, latex rubber foam,
convoluted foam ("egg create foam"), EVA foam, VN 600 foam, EvIon foam,
Ariaprene or Ariaprene-like
material, impact hardening foam, and/or any combination thereof. The at least
one foam layer may
have an open-cell structure or closed-cell structure. The foam layer can be
further tailored to obtain
specific characteristics, such as anti-static, breathable, conductive,
hydrophilic, high-tensile, high-tear,
controlled elongation, and/or any combination thereof.
[00071] Figures 4 through 6 depict another exemplary embodiment of impact
mitigating
structures comprising undulating structures 100, including chevron-shapes,
"zig-zag" and/or
herringbone patterned structures that form "V" shapes as shown in FIG. 21. In
this embodiment,
Figures 4A-46 depict one embodiment of an undulating impact structure 100. The
undulating impact
structures 100 comprises a plurality of undulating walls 110 and a plurality
of lateral support walls or
support members 120, the plurality of undulating walls 110 forming an array,
each of the plurality of
undulating walls 110 having a sinusoidal shape and a height. The plurality of
lateral support walls or
support members 120 can reinforce, connect and/or support the plurality of
undulating walls 110 (e.g.,
chevron, zig-zag or herringbone structures). Each of the undulating structure
100 may further comprise
a vertical height 130. In various embodiments, the lateral walls 120 may
extend the entire vertical
height 130 of the undulating structure 100, or undulating chevron, zig-zag or
herringbone structure,
while in other embodiments the lateral walls 120 may not extend the full
vertical height of the chevron
structures and/or may partially extend substantially perpendicular along the
upper, lower and/or center
portion(s) of the undulating walls 110. "Substantially" may comprise angles of
70-110 degrees.
Alternatively, the undulating walls 110 may have different configurations,
including herringbone,
chevron structures or zig-zag patterns that may comprise of lateral walls 120
with frustum or cone-
shape and/or configuration. FIG. 20 depicts one embodiment of a frustum shaped
chevron patterned
lateral wall, where the lateral wall has a top surface and a bottom surface,
the top surface has tapered
walls that extend from the top surface to the bottom surface. The bottom
surface may further comprise
an enlarged base or flange that extends outward from the bottom surface. The
top surface may be
radiused, chamfered and/or beveled. For example, the chevron shapes or
structures may be
manufactured from materials with different durometers. Such durometers may
comprise a range from
70 Shore A to 70 Shore D.
[00072] Figures 5 and 6 depict one embodiment of an undulating impact
mitigation structure
100 that may be covered or uncovered. Each of the plurality of undulating
impact mitigation structure
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100 may be sized and configured to a custom shape. The custom shape may
desirably allow mirror
images of the custom shape (e.g., left and right structures) for ease of
manufacturing. Each of the
plurality of undulated impact mitigation structure 100 may be affixed directly
onto the boot layer or
liner or they may include a covering to form an undulated impact mitigation
pad 150. The undulated
impact mitigation pad 150 may comprise a first layer, a second layer and an
undulated impact mitigation
structure 100. Figure 6 shows one exemplary embodiment of a custom shaped
undulated impact
mitigation structure 160. The custom shaped undulated impact mitigation
structure 160 may comprise
a plurality of undulating walls 180, at least one lateral support wall or
support member 170, and a
border 190. The plurality of lateral support walls or support members 170 can
reinforce, connect and/or
support the plurality of undulating walls 180 (e.g., chevron, zig-zag or
herringbone structures). Each of
the plurality of undulating walls 180 may further comprise a wall height 140.
In various embodiments,
the lateral walls 170 may extend the entire vertical height 200 of the
undulating structure 160, or
undulating chevron, zig-zag or herringbone structure, while in other
embodiments the lateral walls 170
may not extend the full vertical height of the chevron structures and/or may
partially extend
substantially perpendicular along the upper, lower and/or center portion(s) of
the undulating walls 180.
"Substantially" may comprise angles of 70-110 degrees. Alternatively, the
undulating walls 180 may
have different configurations, including herringbone, chevron structures or
zig-zag patterns that may
comprise of lateral walls 170 with frustum or cone-shape and/or configuration.
The border 190 may
surround at least a portion or the entire plurality of undulating walls 180.
The undulating wall height
140 may comprise an elongated height that facilitates a buckling deformation,
the buckling being a
sudden lateral deflection away from each of the plurality of undulating wall
180 longitudinal axis.
[00073] In various embodiment, the impact mitigation structures can range
in size or wall height
140 from 1 to 20 mm thick, and may incorporate different thicknesses of
structure(s) throughout one
single impact mitigation pad and/or pad assembly, and among the several impact
mitigation pads
and/or pad assemblies in the soft shell helmet, to desirably accommodate
different frequencies, types
and/or magnitudes of impact anticipated for the wearer. Such design can be
sport and/or player
specific, including various designs for sports such as soccer, etc.
[00074] In various additional embodiments, the impact mitigating
structures may comprise
filaments (longitudinally extending members that deform non-linearly in
response to an impact source),
polygonal structures (in an array or segmented), single-layered impact layers
or multi-layered impact
layers, and/or any combination thereof. Furthermore, the impact mitigating
structures may be provided
in a continuous array or a segmented array. The thin, longitudinally extending
members may be shaped
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and configured to deform non-linearly in response to an impact force. The non-
linear deformation
behavior is expected to provide improved protection against high-impact
forces, and/or oblique forces.
The non-linear deformation behavior can be described by at least a portion of
the filament's individual
and/or en-masse stress-strain profile. The non-linear stress-strain profile
can illustrate that there is an
initial rapid increase in resistance to an impact force, followed by a change
in slope that may be flat,
decreasing or increasing slope, followed by a third region with a different
slope.
[00075] If desired, the impact mitigating structures can comprise
laterally supported filaments.
The impact mitigating structures can comprise at least a portion of a
plurality of filaments that are
interconnected by laterally positioned walls or sheets in a polygonal
configuration. At least a portion of
the filaments arranged in a hexagonal pattern interconnected by laterally
positioned walls.
Alternatively, other polygonal structures known in the art may be
contemplated, such as triangular,
square, pentagonal, hexagonal, septagonal, octagonal, etc. A plurality of
sheets or lateral walls can be
secured between adjacent pairs of filaments with each filament having a pair
of lateral walls attached
thereto. In the disclosed embodiment, the lateral walls can be oriented
approximately 120 degrees
apart about the filament axis, with each lateral wall extending substantially
along the longitudinal length
of the filament. Alternatively, the hexagonal pattern may allow at least one
lateral wall to be
asymmetric, which the angle of the wall may be between 90 to 135 degrees. The
shape, wall thickness
or diameter, height, and configuration of the lateral walls and/or filaments
may vary to "tune" or
"tailor" the structures to a desired performance. For example, one embodiment
of a hexagonal
structure may have a tapered configuration. The hexagonal structure can have a
top surface and a
bottom surface, with the bottom surface perimeter (and/or bottom surface
thickness/diameter of the
individual elements) may be larger than the corresponding top surface
perimeter (and/or individual
element thickness/diameter). In another example, the hexagonal structure can
have an upper ridge.
The upper ridge can also facilitate connection to another structure, such as
an inner surface of a helmet,
an item of protective clothing, and/or a mechanical connection (e.g., a
grommet or plug having an
enlarged tip that is desirably slightly larger than the opening in the upper
ridge of the hexagonal
element).
[00076] Desirably, at least a portion of the elements in the impact
mitigating structures will
desirably buckle and/or deform in response to an incident force, where
buckling may be characterized
by a localized, sudden failure of the filament structure subjected to high
compressive stress, where the
actual compressive stress at the point of failure is less than the ultimate
compressive stress that the
material is capable of withstanding. Furthermore, the at least a portion of
the filaments may be
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configured to deform elastically, allowing the at least a portion of the
filaments to substantially return to
their initial configuration once the external force is removed.
[00077] Furthermore, the polygonal or hexagonal structures may be
manufactured as individual
structures. The manufacturing individual polygonal or hexagonal structures may
include extrusion,
investment casting or injection molding process. Each individual polygonal or
hexagonal structure may
be affixed directly to the inner or outer surface of the helmet outer layer,
inner or outer surface of the
helmet inner layer, the inner or outer surface of the helmet impact absorbing
layer, and/or any
combination thereof. Also, they may have the same shape and configuration with
repeating
symmetrical arrangement or asymmetrical arrangement and/or different shape and
configurations with
repeating symmetrical arrangement or asymmetrical arrangement.
[00078] Conversely, the polygonal or hexagonal structures may be
manufactured directly into a
patterned array affixed to at least one base material. The base material may
be manufactured with a
polymeric or foam material. The polymeric or foam material may be elastic to
allow it to be easily bent,
twisted or flexed to conform to complex surfaces. Alternatively, the polymeric
and/or foam material
may be substantially rigid. The manufacturing of each patterned array of
polygonal or hexagonal
structures may include extrusion, investment casting or injection molding
process. Each patterned array
of polygonal or hexagonal structure and/or the base material may be affixed
directly to the liner.
[00079]
[00080] If desired, a regional location and/or distribution of the
segmented arrays on the boot
layer may be positioned to accommodate a desired "position-specific" purpose.
In various
embodiments, the segmented arrays may include regionally specific arrays, such
as the front, jaw,
midline (surrounding the majority of the circumference to include right side,
mid-back and left side),
top, lower back layer 1 and lower back layer 2.
[00081] The impact mitigating structures may be bonded or coupled directly
to a boot layer or
liner. The impact mitigating structures and the boot layer may further
comprise at least one top
covering and one bottom covering. The at least one top covering and at least
one bottom covering may
comprise a resilient fabric that may include a two-way or four-way stretch
material, any elastic material,
a soft-flexible material, and/or any combination thereof. The at least one top
covering and at least one
bottom covering may be the same material, or they may be different materials.
The impact mitigating
structures and the boot layer may be coupled to a foam layer or other layer.
Such coupling may be
accomplished by using adhesives, molding, heat and/or material welding,
sintering or any other method
known in the art. The foam layer may comprise a single layer or multiple
layers, which any of the layers
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may be comprised of various types of foam, such as TPU foam, Poron XRD foam,
impact resistant foam,
compression foam, and/or any combination thereof. All of the segmented impact
mitigating structures
may be coupled to the base layer or at least a portion of the segmented impact
mitigating structures
may be coupled to the base layer. Alternatively, the impact mitigating
structures may be "free-floating"
within the base layer. The base layer can be coupled around the complete
perimeter of the impact
mitigating structure completely enclosing the impact mitigation structure, but
still allowing the impact
mitigation structure to "freely-float" and/or be fixed within the base layer.
In addition, the base layer
can be coupled around at least a portion of the perimeter of the impact
mitigating structure leaving an
opening, such that the impact mitigation structure "freely-floats" within base
layer. The opening may be
sized and configured to allow the impact mitigation structure to be removably
coupled within the base
layer, and easy replacement of the impact mitigation structure. The opening
may be closed using
various mechanical methods known in the art, including stitching, snaps,
Velcro, magnets, and/or any
combination thereof.
[00082] In various embodiments, each of the individual impact mitigating
structures or
patterned arrays of mitigating structures may be have at least one covering to
form individual pads, pad
assemblies or pad arrays. The at least one covering may be a loosely or
tightly woven fabric. The fabric
may be polymeric, such as polypropylene, polyethylene, polyester, nylon, PVC,
PTFE, and/or any
combination thereof. The fabric may be 2-way or 4-way stretch material.
Furthermore, the at least one
covering may be breathable and wick away moisture easily from the skin while
carrying out various
sporting and athletic activities. For example, the covering may completely or
continually cover an entire
array of impact mitigating structures (not shown). Conversely, the covering
may cover at least a portion
of an entire array of impact mitigating structures. Furthermore, the covering
may cover segmented
arrays of impact mitigating structures or individual impact mitigating
structures.
[00083] In various embodiments, each of the individual impact mitigating
structures or
patterned array of mitigating structures may have at least one foam layer. The
at least one foam layer
can include polymeric foams, quantum foam, polyethylene foam, polyurethane
foam (foam rubber), XPS
foam, polystyrene, phenolic, memory foam (traditional, open cell, or gel),
impact absorbing foam,
compression foam, latex rubber foam, convoluted foam ("egg create foam"), EVA
foam, VN600, EvIon
foam, impact hardening foam, and/or any combination thereof. The at least one
foam layer may have
an open-cell structure or closed-cell structure. The at least one foam layer
can be further tailored to
obtain specific characteristics, such as anti-static, breathable, conductive,
hydrophilic, high-tensile, high-
tear, controlled elongation, and/or any combination thereof.
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[00084] One particularly advantageous feature of the designs described
herein is the ability to
mold and/or assemble the impact layer and various other helmet components in a
flat plane, which can
make the tool design and construction much easier. For the best possible fit
on all different head
shapes, an ideal material to wrap the head with is a four way stretch material
or a material that can
stretch in all directions, and the impact mitigating structures can be
attached to this type of a material
and, due to the unique design, can flex and take shape over a complex
contoured shape without
wrinkles. Finally, the walled impact structure allows for an impact protective
layer that easily allows for
moisture vapor to pass thru, allowing the users head to naturally cool when
wearing, unlike other
impact layers that limit this ability.
[00085] For example, Figures 7A-76 depicts different exemplary embodiments
of a helmet "boot
layer," "boot" construction or "liner". Figures 7C-7D depicts one embodiment
of a boot layer or liner
230, the boot layer or liner 230 may comprise at least one single material
layer or a plurality of material
layers. Each of the plurality of layers may be manufactured to accommodate and
protect the desired
region of the player's head. The desired regions may include the front, upper
sides (right and left) lower
sides (right and left), ridge (top of head), mid back, lower back, jaw,
temples, and/or any combination
thereof. The boot layer may comprise one material layer. Alternatively, the
boot layer or liner 230 may
comprise at least one first material 240 and at least one second material 260.
In one preferred
embodiment, the boot layer or liner 230 may comprise at least one of a first
material 240, at least one
second material 260, and at least one foam layer 250. The at least one foam
layer 260 may comprise
EVA foam, Ariaprene or an impact mitigation structure. The at least one foam
layer 250 being affixed to
the at least one first 240 and at least one second material 260, and/or
disposed between the at least
one first material 240 and the at least one second material 260. The at least
one first 240 or at least one
second material 260 may be a two- or four-way stretch fabric, and/or a sweat
wicking or anti-microbial
fabric, where the top or first material and/or bottom or second material
covering may be the same
material or the at least one top and bottom covering may be different
materials. For example, the boot
layer first material 240 or second material 260 comprises at least one of a
skin contact fabric material
(which could comprise a wicking material, an anti-microbial material such as
Neoprene, Ducksan Power
Net, Diamond pattern) , an Ethylene-Vinyl Acetate (EVA) foam layer or an
Ariaprene foam layer, a 4-way
stretch material, and/or any combination thereof, each and/or all of which
could be bonded together
using heat pressing techniques, vibration welding techniques or similar
construction techniques, known
to those of skill in the art.
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[00086] Accordingly, the boot layer or liner 230 may form a seam 270, the
seam 270 may be
formed through a heat press, ultrasonic welding or vibration welding
techniques to surround the
perimeter of the boot liner 230. The foam layer can include polymeric foams,
quantum foam,
polyethylene foam, polyurethane foam (PU foam rubber), XPS foam, polystyrene,
phenolic, memory
foam (traditional, open cell, or gel), impact absorbing foam, compression
foam, latex rubber foam,
convoluted foam ("egg create foam"), EVA foam, VN 600 foam, EvIon foam,
Ariaprene or Ariaprene-like
material, impact hardening foam, and/or any combination thereof. The at least
one foam layer may
have an open-cell structure or closed-cell structure. The foam layer can be
further tailored to obtain
specific characteristics, such as anti-static, breathable, conductive,
hydrophilic, high-tensile, high-tear,
controlled elongation, and/or any combination thereof.
[00087] As best seen in Figures 8A through 8C, various configurations of
boot components can
be constructed in simple and/or complex shapes, including a "butterfly" shape
8A, which allows helmet
components to be manufactured in a "flat" configuration, and then ultimately
be flexed and/or
"deformed" into a desired helmet shape that can easily take the complex
contoured shape of the head
and/or that can be combined with other shaped/sized components. In addition,
the various
components described herein could be amendable to additive or "3-D"
manufacturing and/or printing
techniques.
[00088] Figure 9A through 9E depict one exemplary manufacturing technique
for forming a boot
layer or liner 290. The boot layer or liner 290 may comprise a first material
300, a second material 310
and a foam layer 280. In this embodiment, an initial step is to laser cut a
desired shape of the foam
layer 280. More specifically, the foam layer 280 may comprise of EVA foam or
Ariaprene. The foam
layer is then laminated with a first material 300 and a second material 310.
The first 300 or second 310
material may have a size and shape that is larger than the foam layer 280. The
first 300 or second 310
material may comprise a 4-way stretch material (e.g., Ducksan DS4015-645 Power
Net) and/or the
second material 310 may comprise a 4-way stretch material (e.g., Diamond
Pattern). The resulting
bonded construct can then be die or laser cut to a desired shape, and
subsequently utilized to construct
the boot. Alternatively, Figure 17 shows another embodiment for forming a boot
layer. Figures 9C
illustrate how the first 300 and second 310 materials are cut into the desired
shape of the foam layer
280. The boot layer or liner 290 may be positioned over an edge compress tool
320, ensuring the liner
edges are aligned with the edge compress tool 320 edges. The edge compress
tool 320 having a recess
330 that conforms to the desired shape of the foam layer 280. A die cut liner
340 is positioned over the
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boot layer or liner 290 and inserted into the recess 330 firmly to "cut" the
desired shape. Accordingly,
Figure 9E illustrates the finished boot layer or liner 350 with the compressed
and cut edges.
[00089] Figures 10A-10C depicts two exploded cross-sectional views of an
exemplary
embodiments of multi-layer construction of a soft helmet. Figure 10A depicts a
soft-shell helmet 360
that comprises at least one impact mitigation structure 370 may be affixed to
the boot layer or liner 390.
The at least one impact mitigation structure 370 may comprise a flange 380
that can be welded, glued or
stitched 430 to the boot layer or liner 390. The boot layer or liner 390 may
comprise a first material 400,
a second material 420 and a foam layer 410, where the foam layer 410 is
disposed between the first
material 420 and a second material 520. Alternatively, the soft-shell helmet
440 may comprise, wherein
an impact absorbing structural component 370 can be attached to the head boot
and/or encapsulated
within a boot "pouch." Figure 10C depicts a soft-shell helmet 440 that
comprises at least one impact
mitigation pad 450, the at least one impact mitigation pad 450 comprises a
first material 460, a second
material 480, and/or an impact mitigation structure 370. The at least one
impact mitigation pad 450
may further comprise a third material 470. The second material 480 may extend
beyond the width of
the impact mitigation structure 370 to form a flange, and the first material
460 may encapsulate the
impact mitigation structure 370 to form a pouch. A glue strip 490 may be
placed under a portion of the
second material 480 flange, such that the glue strip 490 may surround the
perimeter of the impact
mitigation structure 370. A plurality of impact mitigation pads 450 may be
affixed to the boot layer 390.
The boot layer or liner 390 may comprise a first material 400, a second
material 420 and a foam layer
410, where the foam layer 410 is disposed between the first material 420 and a
second material 520.
The first material 460, the second material 470, and/or the third material 480
may comprise of the same
fabrics or different fabrics. The fabrics may comprise a 2-way stretch
material, a 4-way stretch material,
and/or a foam layer (e.g., a stretch knit, a stretch air mesh, and/or an open
cell foam). The foam layer
can include polymeric foams, quantum foam, polyethylene foam, polyurethane
foam (PU foam rubber),
XPS foam, polystyrene, phenolic, memory foam (traditional, open cell, or gel),
impact absorbing foam,
compression foam, latex rubber foam, convoluted foam ("egg create foam"), EVA
foam, VN 600 foam,
EvIon foam, Ariaprene or Ariaprene-like material, impact hardening foam,
and/or any combination
thereof. The at least one foam layer may have an open-cell structure or closed-
cell structure. The foam
layer can be further tailored to obtain specific characteristics, such as anti-
static, breathable, conductive,
hydrophilic, high-tensile, high-tear, controlled elongation, and/or any
combination thereof.
[00090] Figures 11A through 11G depict one exemplary technique for forming
pockets creating
an impact mitigation pad, where the materials can encapsulate the impact
absorbing structural
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components. In this embodiment, a thermoplastic polyurethane (TPU) film 510 is
initially placed into a
TPU forming tool 500, which then closes and forms a TPU film or a first
material 540within the each of
the cavities/pockets 530 of the tool 520. Then, a plurality of impact
absorbing structures 550 and
associated open cell polyurethane foam layers 560 (the foam layer can be 1 mm
to 5 mm thick) can be
inserted into the pockets that form the first material 540 (Figure 11D), and a
hotmelt layer 570 with
release paper 580 can be applied to the formed TPU 520 (Figure 11E).
Alternatively, the pockets or the
impact mitigation pads can be bonded to the liner using ultrasonic welding or
high-frequency welding
(e.g., using a controlled vibration of the tooling to partially liquify the
TPU material itself and weld the
flanges or base of the pocket to the liner). The pockets can then be die cut
590 (Figure 11F) and
removed from the TPU form tool 520. Figure 11G depicts an isometric view of
the plurality of individual
impact mitigation pads 600 after they were die cut 590 into separate pads.
Figure 16 depicts an
alternative method for forming pockets that encapsulate the impact absorbing
structure.
[00091]
Figures 12A through 12C and Figure 15 illustrate one exemplary technique for
bonding
the impact mitigation pads 600, i.e., the pockets and impact absorbing
structures, to the liner or at least
one boot layer. In this embodiment, the impact mitigation pads 600 or pockets
are first inserted into
the tool cavity 620, and then the liner component 620 is inserted into or over
the tool 610. Heat and
pressure are applied by the tool 610 in a known manner, and then the tool 610
is opened and the
completed part removed for use and/or further assembly. Alternatively, the
liner and/or the boot layer
620 can be bonded together using ultrasonic welding or high-frequency welding
(e.g., using a controlled
vibration of the tooling to partially liquify the materials and weld the liner
to the boot layer together).
Figure 12C depicts a front view of one exemplary embodiment of a completed
soft shell helmet 630
comprising one or more impact mitigation pads 600 and a liner 620.
[00092]
Figures 13A-13C depict one embodiment of a soft shell helmet design as
similarly shown
in Figures 2A and 3A. Figures 13A-136 show a side and a front view of the soft-
shell helmet of Figures
2A-3A. The soft shell helmet comprises a liner 50 and at least one impact
mitigation structure 60 affixed
to the liner 50. The soft shell helmet may further comprise an ear aperture
70, the ear aperture 70 may
be sized and configured to fit a wearer's ear shape. Figure 13C illustrates a
covered soft-shell helmet 45,
the covered soft-shell helmet 45 comprises a cover 55, a liner 50, and at
least one impact mitigation
structure 60 affixed to the liner 50. The cover 55 would encapsulate the
entire liner 50 and at least one
impact mitigation structure 60 assembly to provide protection from sweat
and/or anti-microbial
protection.
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[00093] FIG. 14 and 15A-15C illustrates one exemplary embodiment for
forming a soft shell
helmet 640. The soft shell helmet 640 may comprise a plurality of liner
assemblies, where each of the
plurality of liner assemblies 650 comprise a liner 660 and at least one impact
mitigation pad 650. Each
of the plurality of liner assemblies 650 or segments are connected to an
adjacent liner segments or liner
assemblies 650. The liner assemblies 650 or segments or a plurality of boot
layers can be connected to
each other using various methods known in the art. Such connections may
include ultrasonic welding,
RF welding, stitching, gluing, stretch seam taping, Velcro, riveting, and/or
any combination thereof.
More specifically, each of the liner assemblies 650 may have the liner 660
that extended edge a certain
width beyond the at least one impact mitigation pad 650, which the liner edge
680 extends allows the
edges 680 to be coupled to each other to form a soft-shell helmet 640. The
liner segments or a plurality
of boot layers may provide for a border or periphery that surrounds each liner
segment to provide
additional features. Such additional features may include a snap button pose
for a chinstrap mount (not
shown), through-holes 670, and/or a seam edge to affix the adjacent edge to
each other.
[00094] In various embodiments, the impact mitigation structures can
incorporate varying
offsets (i.e., array thickness as measured in a perpendicular direction
outward from the surface of the
wearer's head), including offsets of 4 to 6 millimeters, 7 to 9 millimeters
and/or 11 to 13 millimeters.
The soft helmets can be provided in a variety of sizes (3 sizes, in at least
one example), with each size
desirably accommodating a range of head sizes, with overlap between each
member of each range.
[00095] In various embodiments, the overall thickness of the soft helmet
could be 8 millimeters
or less, which is a significant improvement over competitive designs that can
be 15 to 20 millimeters or
more in thickness.
[00096] Figures 16A-16I3 depict an alternative embodiment to manufacture
at least one impact
mitigation pad 690. Figure 16A depicts an impact mitigation pad 690 that
comprises a first material 700,
a second material 740, and/or an impact mitigation structure 710. The at least
one impact mitigation
pad 690 may further comprise a third material 720. The second material 740 may
extend beyond the
width of the impact mitigation structure 710 to form a flange, and the first
material 700 may
encapsulate the impact mitigation structure 700 to form a pouch. The first
material 700 contacts the
second material 740 in order to create a seam 730, the seam 730 may be created
with ultrasonic
welding, RF welding, stitching, gluing, stretch seam taping, Velcro, riveting,
and/or any combination
thereof. The first material 460, the second material 470, and/or the third
material 480 may comprise of
the same fabrics or different fabrics. The fabrics may comprise a 2-way
stretch material, a 4-way stretch
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material, and/or a foam layer (e.g., a stretch knit, a stretch air mesh,
stretch poly, and/or an open cell
foam). Figure 1613 illustrates various embodiments of impact mitigation pads.
Figures 17A-17C depict different views of another embodiment of a liner 750.
The liner 750 may
comprise a first material 760, a second material 780, and a foam layer 770,
the foam layer 770 disposed
between the first material 760 and the second material 780. The first material
760, the second material
780, and/or the foam layer 770 may comprise of the same fabrics/materials or
different
fabrics/materials. The fabric/materials may comprise a 2-way stretch, a 4-way
stretch, a foam material
(e.g., EVA or Ariaprene). The liner 750 may have sealed seam 790 that
surrounds the perimeter of the
liner 750. The sealed seam may be approximately 1 mm to 5 mm.The foam layer
can include polymeric
foams, quantum foam, polyethylene foam, polyurethane foam (PU foam rubber),
XPS foam,
polystyrene, phenolic, memory foam (traditional, open cell, or gel), impact
absorbing foam, compression
foam, latex rubber foam, convoluted foam ("egg create foam"), EVA foam, VN 600
foam, EvIon foam,
Ariaprene or Ariaprene-like material, impact hardening foam, and/or any
combination thereof. The at
least one foam layer may have an open-cell structure or closed-cell structure.
The foam layer can be
further tailored to obtain specific characteristics, such as anti-static,
breathable, conductive, hydrophilic,
high-tensile, high-tear, controlled elongation, and/or any combination
thereof.
[00097] Figure 20-21 depict another embodiment of an undulating impact
mitigation structure
810. The undulating impact structure 810 having a plurality of undulating
walls 820 forming an array,
each of the undulating walls 820 having a cross-sectional shape 830, the cross-
sectional shape 830
having a first portion 840 and a second portion 850, the second portion 840
comprises a longitudinal
member that extends perpendicular from the first portion 840. The second
portion 850 having a length
860 and a width 870 to form an aspect ratio. If the length is greater than the
width, a high aspect ratio
structure, the second portion 850 can be more prone to buckling, the buckling
being a sudden lateral
deflection away from the longitudinal axis of the undulating walls 820. The
aspect ratio may be
between 3:1 to 1,000:1, where the length is greater than the width. The cross-
sectional shape may
comprise a solid or hollow shape. The longitudinal member may comprise a
conical or frustum shaped
structure, but it also may comprise a square, cylinder, triangle, shaped
structure. The undulated walls
820 may comprise herringbone shape 880, chevron shape 890, a zig zag shape
900, and/or any
combination thereof as shown in Figure 21Figures 22A-22E depict an alternative
embodiment of a full-
coverage soft shell helmet. The full coverage soft shell helmet may comprise
at least one of a boot layer
or liner, one or more individual impact pads or individual impact pad
assemblies, a chinstrap, ear
protection elements and/or any combination thereof. The soft shell helmet 910
comprising a liner 920,
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one or more impact mitigation pads 930. The one or more impact mitigation pads
930 are affixed to the
liner 920. The liner 920 may comprise apertures 940 that allow ventilation.
The at least one "boot
layer," or "liner" 920 may comprise at least one material layer or a plurality
of material layers. The at
least one boot layer 920 may comprise a single material layer. Alternatively,
the at least one boot layer
920 may comprise a first material and a second material. The at least one boot
layer 920 may be
custom manufactured to fit the desired head of the player and/or be
manufactured to standard sizes
(small, medium, large, x-large, etc.) The at least one boot layer 920 may be
manufactured to
accommodate and protect the desired region of the player's head. The desired
regions may include the
front, upper sides (right and left) lower sides (right and left), ridge (top
of head), mid back, lower back,
jaw, temples, and/or any combination thereof. In a preferred embodiment, the
at least one boot layer
920 may comprise a first material, a second material, and a foam layer and/or
any combination thereof.
[00098] The one or more individual impact pads or individual impact pad
assemblies may
permanently and/or removably affixed or coupled to the at least one boot layer
or liner and regionally
placed around the player's head for enhanced protection. The one or more
individual impact pads
and/or impact pad assemblies may be desirably positioned on different regions
of the head, including
the frontal section, top or ridge section, lower back, mid-back, left side and
front side, temples, jaw
region and/or any combination thereof. For example, Figures 23A-236 and 24
depict one embodiment
of a front impact pad assemblies 950, 980 and/or a rear impact pad assemblies
970, which each of the
front 950 and rear 970 assemblies comprise one or more impact mitigation pads
960.
[00099] Figures 25A-256 and 26A-266 depict another exemplary alternative
embodiment of an
individual impact mitigation pad 990. The at least one or more individual
impact mitigation pads 980
may comprise at least one impact structure 1040 at least one first layer or
material 1000. The first layer
or material 1000 comprises a flange 1010, the flange 1010 surrounds a
perimeter of one end of the first
layer or material 1000 and at least one recess 1020 forming a pocket, the
pocket having a pocket height
1050, and the pocket may be shaped and configured to receive the impact
mitigation structure 1040.
The first layer or material 1000 may further comprise ventilation holes
1030the pocket having a pocket
height 1050 the impact mitigation structure 1040 disposed within the pocket.
The impact mitigation
structure may comprise a portion of filaments, laterally supported filaments,
auxetic structures, and/or
undulating structures. In one embodiment, the impact mitigation structure 1040
can comprise
undulating structures. The undulating structures comprise a plurality of
spaced apart elongate walls,
each of the plurality of elongate walls having a height and an undulated
pattern, each of the plurality of
elongate walls having a cross-sectional shape including a first lower portion
and a second upper portion,
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the first lower portion comprising a base having a cross-sectional width and a
height, the second upper
portion comprising an upwardly extending longitudinal member, the upwardly
extending longitudinal
member extending generally perpendicular from the base and having a cross-
sectional width and a
height, the base width is greater than the upwardly extending longitudinal
member width and the base
height is less than the upwardly extending longitudinal member height; and at
least one support
member, the at least one support member extending at least a portion of a
length of the plurality of
spaced apart elongate walls Furthermore, the plurality of spaced apart
elongate walls is disposed within
the pocket, where the plurality of spaced apart walls having an end that is
flush with the perimeter of
the pocket. Alternatively, the plurality of spaced part walls having an end
that extends beyond the
perimeter of the pocket or below the perimeter of the pocket. The height and
undulated pattern may
be uniform or non-uniform. Furthermore, each of the individual impact
mitigation pads 990 may
comprise a one-piece assembly that integrates the impact mitigation structure
within the at least one
first layer. The one-piece impact mitigation structure may be injection
molded, 3D printed, casted,
thermoformed and/or die cut with the first layer as a one-piece construct.
[000100] Figures 27A-276 depicts the impact mitigation pad assembly 1060. The
impact
mitigation pad assembly 1060 comprises an impact mitigation pad 990, at least
one first layer 1070 and
at least one second layer 1080. Alternatively, the impact structure assembly
may further comprise a top
and/or a bottom covering. The at least one first layer 1070 or the at least
one second layer 1080 may be
coupled and/or affixed to the impact mitigation pad 990, the impact mitigation
structure (not shown)
and/or impact structure assembly. The at least one first layer or the at least
one second layer may
include a 2-way stretch material, a four-way stretch material, at least one
foam layer, at least one
polycarbonate layer or a force distribution layer, a hotmelt layer, boot layer
and/or any combination
thereof. The at least one first and/or at least one second covering may be a
two- or four-way stretch
fabric (e.g. Lycra), where the top and bottom covering may be the same
material or the at least one top
and bottom covering may be different materials. The at least one top covering
and/or at least one
bottom covering may be coupled to the impact mitigation structure and/or the
impact mitigation
structure assembly as shown by Figures 28A-286. The coupling may include
stitching, hook and loop
fasteners, snaps, adhesive, melting, any form of welding known in the art. The
polycarbonate layer can
be thin, flexible, yet substantially rigid to assist with absorption of the
forces and reduce wear/tear. The
foam layer can include polymeric foams, quantum foam, polyethylene foam,
polyurethane foam (PU
foam rubber), XPS foam, polystyrene, phenolic, memory foam (traditional, open
cell, or gel), impact
absorbing foam, latex rubber foam, convoluted foam ("egg create foam"), EVA
foam, VN600 foam, EvIon
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foam, Ariaprene or Ariaprene-like material, impact hardening foam, compression
foam, and/or any
combination thereof. The at least one foam layer may have an open-cell
structure or closed-cell
structure. The foam layer can be further tailored to obtain specific
characteristics, such as anti-static,
breathable, conductive, hydrophilic, high-tensile, high-tear, controlled
elongation, and/or any
combination thereof. Each of the impact pad assemblies 1060 may be affixed to
a liner 1090. The
affixation may comprise ultrasonic welding, gluing, hot melt, etc. The one or
more individual impact
pads and/or impact pad assemblies 1060 may be desirably positioned on
different regions of the head,
including the frontal section, top or ridge section, lower back, mid-back,
left side and front side, temples,
jaw region and/or any combination thereof.
[000101] FIG. 29A-29F and/or 30A-30C depict one embodiment of the manufacture
of a full-
coverage soft shell helmet. In one embodiment, creating a plurality of
individual impact pads and/or
individual impact pad assemblies, coupling the plurality of individual impact
pads to a least one boot
layerõ cutting the boot layer to substantially match the perimeter of the
plurality of individual impact
pads leaving a 0 to 6 mm edging, coupling a portion of the booth layer edging
to the proximate base
layer edging to form a circumferential shaped construction. Such process may
be repeated for the front
pad assembly and the rear pad assembly, then coupled to each other to form the
circumferential shaped
construction as shown in FIG. 31A and 318. In one embodiment, the soft shell
helmet 1180 comprises a
front pad assembly 1100 and a back panel pad assembly 1150 and a base layer
1120. Each of the front
panel assembly 1100 and/or the back panel pad assembly 1150 comprises a
plurality of impact
mitigation pads 990 or impact mitigation pad assemblies 1060. The method to
manufacture a soft shell
helmet comprises the steps of die cutting the plurality of foam panels 1110
that substantially conforms
or conforms to the shape and configuration of the plurality of impact
mitigation pads 990 and/or the
plurality of impact mitigation pad assemblies 1060, bonding the foam panels
1110 to a base layer 1120
(e.g., a 2-way or 4-way stretch material), cutting the base layer 1129 with
the plurality of foam panels
1110 to create a custom base layer 1120 that substantially conforms to the
plurality of impact mitigation
pads 990 and/or plurality the impact mitigation pad assemblies 1060, replacing
at least a portion of the
foam panels 1110 with a portion of the plurality of impact mitigation pads 990
and/or the impact
mitigation pad assemblies 1060 and affixing them to the base layer, flexing
the tabs 1140 of the base
layer to conform to the head of a wearer, affixing the remaining the impact
mitigation pads 990 and/or
the impact mitigation pad assemblies 1060 to the base layer.
[000102] Accordingly, the front pad assembly 1100 with the back pad assembly
1150 must be
affixed or coupled together to create the soft shell helmet 1180 as shown in
Figures 31A-31C. The key
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impact mitigation pad 1160 has a first end and a second end. The first end is
affixed to the front pad
assembly 1100 and the second end is affixed to the back pad assembly 1150
creating a seam or stitch
1170. The back pad assembly 1150 is flexed to conform to the head of the
wearer. The back pad
assembly having tabs 1140 that may couple a chin strap (not shown).
[000103] Figures 38A-38G depict different plan views of an alternate
embodiment of a soft-shell
helmet 1380. The soft-shell helmet 1380 may comprise a plurality of impact
pads 1390 and a liner 1400.
The liner may comprise one or more material layers. The one or more material
layers may comprise a 2-
way stretch material, a 4-way stretch material, a foam layer, and/or any
combination thereof. The liner
may further comprise an impact mitigation structure (not shown) and one or
more ventilation holes
1430, 1420.
[000104] The plurality of impact mitigation pads 1390 may comprise an impact
pad assembly.
The impact pad assembly comprises an impact mitigation pad 990, a first
material layer 1070, a second
material layer 1080 as shown in Figures 27A-276. The impact mitigation pad 990
comprises a base
material layer (or first material layer), the first material layer or base
material layer having a first surface
and a second surface, a recess disposed onto a first surface extending towards
the second surface, the
recess having a recess height; and an impact mitigation structure, the impact
mitigation structure
comprising a plurality of spaced apart elongated walls, the plurality of
spaced apart walls disposed
within the recess, each of the plurality of elongated walls having a height, a
width and a undulated
pattern, each of the plurality of elongated walls having a cross-sectional
shape.
[000105] Alternatively, the plurality of impact pads 1390 may comprise a
first material layer or
base material layer having a first surface and a second surface, a recess
disposed onto a first surface
extending towards the second surface, the recess having a recess height; and
an impact mitigation
structure, the impact mitigation structure comprising a plurality of spaced
apart elongated walls, the
plurality of spaced apart walls disposed within the recess, the recess having
a recess height, each of the
plurality of elongated walls having a height, a width and a undulated pattern,
each of the plurality of
elongated walls having a cross-sectional shape.
[000106] Each of the plurality of elongated walls or a plurality of
elongated walls may comprise a
uniform height, width and undulated pattern. Alternatively, each of the
plurality of elongated walls or a
plurality of elongated walls may comprise a non-uniform height, width and
undulated pattern. The
elongated wall height may comprise a range between 6 mm to 1.2 cm. The
undulated pattern may be
may comprise herringbone shape 880, chevron shape 890, a zig zag shape 900,
and/or any combination
thereof as shown in Figure 21. Furthermore, in another embodiment, the
plurality of impact pads 1390
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may comprise only a first material layer or base material layer. Furthermore,
each of the plurality of
elongated wall height is less than, equal to, and/or greater than the recess
height. Also, a plurality of
impact pads 1390 may further comprise ventilation holes.
[000107] In addition, the elongated wall height may be a high-aspect ratio
structure. If the length
is greater than the width, a high aspect ratio structure, the impact
mitigation structure 1370 can be
more prone to buckling, the buckling being a sudden lateral deflection away
from the longitudinal axis of
the elongated walls. The aspect ratio may be between 3:1 to 1,000:1, where the
length is greater than
the width. The cross-sectional shape may comprise a solid or hollow shape. The
longitudinal member
may comprise a conical or frustum shaped structure, but it also may comprise a
square, cylinder,
triangle, shaped structure. The elongated walls may also undergo elastic
deformation, allowing the
elongated walls to return to its initial configuration after an impact. The
first or base material layer 1070
and/or the second material layer 1080 may comprise a 2-way stretch material, a
4-way stretch material,
a polymer or polycarbonate material, and/or a foam layer. The foam layer can
include polymeric foams,
quantum foam, polyethylene foam, polyurethane foam (PU foam rubber), XPS foam,
polystyrene,
phenolic, memory foam (traditional, open cell, or gel), impact absorbing foam,
latex rubber foam,
convoluted foam ("egg create foam"), EVA foam, VN600 foam, EvIon foam,
Ariaprene or Ariaprene-like
material, impact hardening foam, compression foam, and/or any combination
thereof. The at least one
foam layer may have an open-cell structure or closed-cell structure. The foam
layer can be further
tailored to obtain specific characteristics, such as anti-static, breathable,
conductive, hydrophilic, high-
tensile, high-tear, controlled elongation, and/or any combination thereof.
[000108] VENTILATION/CLEANING FEATURES
[000109] In various embodiments, the outer surface of the soft helmet can
externally expose the
various voids within the impact absorbing structures, which could
significantly improve ventilation,
wicking and/or cooling of the helmet and the player beneath (see Figures 138
and 13C), as well as allow
free expression of fluids in water sports such as diving and/or water polo.
Alternatively, an outer layer
of material could be provided which isolates and/or protects the voids, which
could desirably prevent
mud, grass or other soils from contaminating and/or filling the voids, if
desired (see Figure 13A). If
desired, the outer material layer could comprise an over layer of mesh or foam
over the top of the
helmet. In various embodiments, the soft helmet would incorporate machine
washable and/or dryable
materials and/or construction.
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[000110] In various alternative embodiments, some portion of the impact
mitigation structures
may have an outer covering, including outer coverings in some regions of the
soft helmet and with no
outer coverings in other regions of the soft helmet.
[000111] HEAD CAP TOP
[000112] In various embodiments, a soft helmet could include a ridge, dome
or peak section that
covers the top of the wearer's head. This could include one or more impact
absorbing structures and
related components to protect the top of the wearer's head. The peak section
could cover the entire
top of the wearer's head, or some portions thereof, depending upon user desire
and comfort. The
dome or peak section may be removably coupled or permanently integrated. The
dome or peak section
may be removably coupled using methods known in the art, such as stitching,
Velcro (hook & loop),
snaps, magnets, and/or any combination thereof.
[000113] HEADBAND / SWEAT BAND
[000114] In at least one exemplary embodiment, a soft helmet could comprise
a head band or
sweat band structure 800, 1190, 1200 for encircling at least a portion of the
wearer's head, with the
band incorporating at least one impact mitigating structure therein and/or
thereupon (see Figure 18 and
Figure 32A-326, 33A-336, and 346-34C). In such an embodiment, the band could
include a uniform
and/or smooth outer surface, which might provide a more desirable exterior
surface and/or surface
profile for use in sports such as soccer, where impacts with the players
head/head band and the soccer
ball would not significantly degrade ball rebound and play. The headband 800,
1190, 1200 may
comprise hidden stitches that surround the top surface and the bottom surface
of the headband. In one
exemplary embodiment, the headband 1200 may comprise a first portion 1270 and
a second portion
1260. Each of the first portion 1270 and the second portions 1260 comprise a
first material 1220 and a
second material 1230, and an impact mitigation structure 1250, the impact
mitigation structure 1250
disposed between the first material 1220 and the second material 1230. The
first portion 1270 may be
sized and configured to conform to the lower back to mid back region of the
wearer's head, and the
second portion 1260 may be sized and configured to conform to the forehead of
the wearer's head. The
first portion 1270 and the second portion may be affixed by an intermediary
material 1280. Such
intermediary material 1280 may be a 2-way stretch material, a 4-way stretch
material, or a foam layer,
where an internal stitch or seam 1240 is created to affix the first 1270 and
second 1260 portions
together. Figures 33C and 33D show a side view and a front view of one
embodiment of a headband
1200. These views represent the total area in which graphic printing may be
available and can be
directly disposed onto the first material 1220.
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[000115] The headband 800, 1190, 1200 may have different standard sizes. Such
standard sizes
may include, small, medium, large, xlarge, etc. The sizes can have a width or
circumference of 40 to 70
cm. The first material 1220 and the second material 1230 may comprise TLC
AP, with a 65C shore
hardness, a 2-way stretch, and/or a 4-way stretch. The impact mitigation
structure 1250 can be a
portion of filaments, a portion of laterally supported filaments, auxetic
structures, undulating structures,
and/or any combination thereof. The headband may comprise a rear seam 1300
and/or a side internal
stitch or seam 1240.
[000116] In
at least one exemplary embodiment, a "soft" shell helmet can include a
protective
headband. The protective headband may comprise a tubular or generally
cylindrical shape and
configuration, which desirably fits around the circumference of an upper
portion of the wearer's head
(i.e., across the forehead and above a portion of the ears and potentially
covering the mid-back region).
The soft-shell helmet headband may comprise at least one first layer, at least
one second layer, and/or
at least one impact mitigation structure or impact mitigation structure
assembly as shown in Figures
33A-33C and 34. Alternatively, the soft-shell helmet headband may comprise at
least one first layer, at
least one second layer, at least one impact mitigation structure or impact
mitigation structure assembly,
a top covering and/or any combination thereof as shown in Figures. 36A-366.
[000117] The at least one first layer or the at least one second layer may be
one or more of the
following: a foam layer, polycarbonate layer, two- or four-way stretch fabric
(e.g. Lycra), a hotmelt layer,
boot layer and/or any combination thereof. The at least one first layer or at
least one second layer may
be the same material or may be different materials. The polycarbonate layer
can be thin, flexible, yet
substantially rigid to assist with absorption of the forces and reduce
wear/tear. The foam layer can
include polymeric foams, quantum foam, polyethylene foam, polyurethane foam
(PU foam rubber), XPS
foam, polystyrene, phenolic, memory foam (traditional, open cell, or gel),
impact absorbing foam, latex
rubber foam, convoluted foam ("egg create foam"), EVA foam, VN600 foam, EvIon
foam, Ariaprene or
Ariaprene-like material, impact hardening foam, and/or any combination
thereof. The at least one foam
layer may have an open-cell structure or closed-cell structure. The foam layer
can be further tailored to
obtain specific characteristics, such as anti-static, breathable, conductive,
hydrophilic, high-tensile, high-
tear, controlled elongation, and/or any combination thereof, and may be 0.5 mm
to 3 mm thick, and 45-
60cm in diameter. The at least one top covering may be a two- or four-way
stretch fabric that may be
standard sized and/or a custom sized. The custom sized style fabric (see
Figure 36A) that may be added
or removed from soft-shell headband to be washed as shown in Figure 36B. Such
custom style
enclosure can be cut to substantially match the soft-shell helmet headband
shape and configuration.
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[000118] Figures 35A-356 depict one embodiment of an impact mitigation
structure 1250 for
assembly into a soft-shell helmet headband. The method comprises cutting the
impact structure and/or
impact structure assembly to custom shape with tabs 1310 that extends from the
impact mitigation
structure 1250, flexing the tabs 1310 until they connect with a portion of the
impact mitigation structure
1250, the connection may comprise gluing, stitching, welding, etc. The impact
mitigation structure 1250
is affixed to a second material 1230 by creating side internal stitches 1240.
Coupling an intermediary
material or layer 1280 over the side internal stitches 1240 and affix into
position; the intermediary
material or layer 1280 may comprise VN-600 foam layer; coupling the first
material 1220 to the impact
mitigation structure 1250 with at least one or more stiches 1290 (the at least
one or more stitches 1290
may align with the side internal stiches of 1240) to create a headband 1300.
Alternatively, coupling the
impact structure and/or impact structure assembly to first or second layer,
coupling the first or second
layer to the impact structure, impact structure assembly and/or the first or
second layer; alternatively, a
removably coupling a top covering layer over the soft-shell helmet headband
assembly.
[000119] Figures 36A-366 depict an alternative embodiment of a headband 1310.
The headband
1310 may comprise a headband skin 1320 that may be removably coupled to a
standard headband
1300. The headband skin 1310 having a width 1330, the width being 20-40 cm
wide. The headband skin
1310 may be a 2-way stretch or 4-way stretch material with different patterns,
colors and/or logos so
the wearer may have the flexibility of choosing a headband skin 1310 to fit
the wearer's personality.
[000120] Figures 37A-37D depict different views and one exploded view of an
alternate
embodiment of a headband 1340. The headband 1340 may comprise a first portion
1355 and a second
portion 1345, each of the first 1355 and the second 1345 portion comprises at
least a first material 1350
a second material 1360, and an impact mitigation structure 1370. The impact
mitigation structure 1370
may comprise a portion of filaments, a portion of laterally supported
filaments, a portion of undulated
structures, and/or any combination thereof. The first portion 1355 and the
second portion 1345 are
coupled together to form a shape that conforms around the circumference of
wearer's head. The
coupling may comprise stitching, gluing, welding, Velcro, and/or any other
mechanical connection. In
one exemplary embodiment, the impact mitigation structure 1370 is an undulated
structure. The
undulated structure comprises a plurality of spaced apart elongated walls,
each of the plurality of
elongated walls having a wall height and a undulated pattern, each of the
plurality of elongated walls
having a cross-sectional shape, the cross-sectional shape including a first
lower portion and a second
upper portion, the first lower portion comprising a base having a cross-
sectional base width and a base
height, the second upper portion comprising an upwardly extending longitudinal
member, the upwardly
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extending longitudinal member extending generally perpendicular from the base
and having a cross-
sectional longitudinal member width and a longitudinal member height, the base
width is greater than
the longitudinal width and the base height is less than the longitudinal
member height; and at least one
support member, the at least one support member perpendicularly extending at
least a portion of a
length of the plurality of spaced apart elongated walls. The impact mitigation
structure 1370 may
further comprise a border, the border surrounds the perimeter of the impact
mitigation structure 1370,
the border having a border height, the border height substantially equivalent
or equivalent to the wall
height. The wall height may be a range between 6 mm to 1.2 cm. Increasing the
base width will provide
more surface area for contacting the wearer's head and facilitates the
distribution of forces.
[000121] In addition, the wall height and/or the longitudinal member height
may be a high-aspect
ratio structure. If the length is greater than the width, a high aspect ratio
structure, the impact
mitigation structure 1370 can be more prone to buckling, the buckling being a
sudden lateral deflection
away from the longitudinal axis of the elongated walls. The aspect ratio may
be between 3:1 to 1,000:1,
where the length is greater than the width. The cross-sectional shape may
comprise a solid or hollow
shape. The longitudinal member may comprise a conical or frustum shaped
structure, but it also may
comprise a square, cylinder, triangle, shaped structure. The elongated walls
may comprise herringbone
shape 880, chevron shape 890, a zig zag shape 900, and/or any combination
thereof as shown in Figure
21. The elongated walls may also undergo elastic deformation, allowing the
elongated walls to return to
its initial configuration after an impact.
[000122] Furthermore, the at least a first material 1350 and a second
material 1360 may
comprise a foam layer or foam material, a 2-way stretch material and/or a 4-
way stretch material. The
at least a first material 1350 and a second material 1360 may comprise
different materials or the same
materials. In addition, the at least a first material 1350 and a second
material 1360 may further
comprise a coating or laminate that is disposed on an interior surface or an
exterior surface of the at
least a first material 1350 and a second material 1360. Such coating or
laminate may comprise a flexible
fabric or a urethane. The at least a first material 1350 and a second material
1360 may further comprise
one or more ventilation holes 1365, where the one or more ventilation holes
1365 may extend from the
first material 1350 through the second material 1360, and/or the one or more
ventilation holes 1365
may extend a portion from the first material 1350 towards the second material
1350. The foam layer
can include polymeric foams, quantum foam, polyethylene foam, polyurethane
foam (PU foam rubber),
XPS foam, polystyrene, phenolic, memory foam (traditional, open cell, or gel),
impact absorbing foam,
latex rubber foam, convoluted foam ("egg create foam"), EVA foam, VN600 foam,
EvIon foam, Ariaprene
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or Ariaprene-like material, impact hardening foam, compression foam, and/or
any combination thereof.
The at least one foam layer may have an open-cell structure or closed-cell
structure. The foam layer can
be further tailored to obtain specific characteristics, such as anti-static,
breathable, conductive,
hydrophilic, high-tensile, high-tear, controlled elongation, and/or any
combination thereof.
[000123] EAR PROTECTION/SHELL ELEMENTS
[000124] In various embodiments, the soft helmet could incorporate
auxiliary protection features,
such as ear caps or other relative more rigid structures, which could comprise
modular components for
addition to the helmet if desired. As best seen in Figures 19A and 1913, and
ear cap could comprise a
molded thermoplastic cup or shell or a foam material, which desirably fits
within an ear opening of the
soft helmet. The foam material may be compression molded foam to provide a
softer and/or more
compliant construction. The foam material may be comprised of memory foam,
open or closed cell
foam, impact foam, ethylene-vinyl acetate (EVA), thermoplastic elastomer (TPE)
or a EVA-TPE hybrid,
and/or any combination thereof. The cup can include one or more openings to
facilitate sound
transmission, if desired. Desirably, the ear cap will include a central raised
region for accommodating
the ear and ear lobes of the wearer, which can extend through an ear opening
of the helmet, with a
peripheral flange or other feature which can be retained by the helmet (which
stretches around the ear
cap in a desired manner to accommodate ear caps of varying sizes).
[000125] In another exemplary embodiment, the soft-shell helmet may comprise a
chin-strap
buckle. The chin-strap may be integrated with the boot layer and/or as a
separate, independent feature
that may be removably coupled. If the separate, independent chin-strap is
removably coupled, the soft-
shell helmet may include a through hole where a chin strap may be affixed and
a buckle to allow
adjustability. Alternatively, if the chin-strap is integrated with the boot
layer, the chin-strap would be
designed with elasticity to allow the player's chin to stretch the chin-strap
to accommodate the different
"chin" size and configurations. Such chin-straps can help support and/or
retain the soft-shell helmet on
the head of the wearer. The chin-strip may be manufactured using an elastic
material and may include
impact mitigation pads or other impact mitigation structures affixed to the
chin-strap, if desired.
[000126] EYE PROTECTION
[000127] In another embodiment, the soft helmet may comprise a visor, eyewear
and/or eye
shields. The visor may be removably connected/coupled or integrated within the
soft helmet. Such
removable connections may include magnets, buckles, elastic bands, Velcro,
snaps, quick release
mechanism, friction, and/or any combination thereof. The visor may be
manufactured with a polymer
that has specific material characteristics to enhance or protect optical
viewing. For example, such
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characteristics may include a shatterproof material, an anti-fog coating, anti-
glare coating, anti-scratch
coating, an anti-reflective coating, photochromic coating, tinting, UV
coating, prescription based, and/or
any combination thereof. The visor may be substantially flexible and curved to
allow insertion under the
soft helmet. The soft helmet may have a specific visor opening, where the
visor may be positioned. The
visor having a flange surrounding the perimeter may be disposed within the
visor opening, the soft
helmet inner surface may hold the flange of the visor in place. Alternatively,
the visor may have
mechanical connections that allow the visor to be removably connected to the
external surface of the
soft helmet.
[000128] SUPPLEMENTAL PROTECTION CAP
[000129] If desired, a soft helmet could also provide an enhanced
"underlayer" of protection
within an existing protective helmet, such as within a hard, rigid or
substantially rigid shell helmet. In
essence, the soft helmet could be worn as a "skull cap" within the shell
helmet, and provide additional
impact protection thereto.
[000130] CONFIGURABLE HELMET
[000131] In at least one alternative embodiment, a soft helmet may comprise
a cylindrical/round
cap or latticed framework or similar arrangement, that could allow for various
designs and/or
configurations of impact absorbing structures to be added and/or removed from
the helmet structure,
depending upon player preference. For example, the latticed framework may
comprise a hook and loop
fastener surface, that attaches to corresponding surfaces on the impact
absorbing structures. This could
include the placement of impact mitigations structures in desired
locations/arrangements to
accommodate sport specific and/or position specific impact needs, including
the use of impact
protective elements that are modular and/or segmented structures that can be
affixed to the exterior
and/or interior of the soft helmet to achieve a desired helmet.
[000132] The entire disclosure of each of the publications, patent documents,
and other
references referred to herein is incorporated herein by reference in its
entirety for all purposes to the
same extent as if each individual source were individually denoted as being
incorporated by reference.
[000133] The invention may be embodied in other specific forms without
departing from the
spirit or essential characteristics thereof. The foregoing embodiments are
therefore to be considered in
all respects illustrative rather than limiting on the invention described
herein. The scope of the
invention is thus intended to include all changes that come within the meaning
and range of equivalency
of the descriptions provided herein.
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[000134] Many of the aspects and advantages of the present invention may be
more clearly
understood and appreciated by reference to the accompanying drawings. The
accompanying drawings
are incorporated herein and form a part of the specification, illustrating
embodiments of the present
invention and together with the description, disclose the principles of the
invention.
[000135] Although the foregoing invention has been described in some detail by
way of
illustration and example for purposes of clarity of understanding, it will be
readily apparent to those of
ordinary skill in the art in light of the teachings of this invention that
certain changes and modifications
may be made thereto without departing from the spirit or scope of the
disclosure herein.
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