Note: Descriptions are shown in the official language in which they were submitted.
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IMPACT PROTECTION SYSTEM
Background of the Invention
[0001] The present invention relates broadly to an impact protection system
and in one
example to a wearable impact protection system, such as a helmet.
Description of the Prior Art
[0002] The reference in this specification to any prior publication (or
information derived from
it), or to any matter which is known, is not, and should not be taken as an
acknowledgment or
admission or any form of suggestion that the prior publication (or information
derived from it)
or known matter forms part of the common general knowledge in the field of
endeavour to
which this specification relates.
[0003] It is known to provide impact protection systems, such as helmets.
Traditional helmets
include a rigid outer shell overlaying a deformable material. When struck by
an object, the
other rigid shell tends to dissipate forces, and prevent penetration by the
object, whilst the
deformable material acts to absorb the forces. Whilst such systems can provide
a high degree
of protection, they tend to be heavy, unwieldly and difficult to transport, as
well as being
uncomfortable to wear for physical activities, such as cycling, skiing,
snowboarding or the like.
[0004] A number of attempts have been made to address such deficiencies. For
example, US
5,661,854 describes a flexible helmet with an outer layer of impact resistant
segments and an
inner layer of energy absorbent structures. The segments are connected by
flexible elastic
panels and an annular crown structure. While enabling a helmet with at least
some degree of
flexibility, the helmet can allow gaps between the impact resistant segments,
thereby having
the potential to allow penetration by a sharp object in these locations.
[0005] US 7,207,072 describes a helmet with movable parts to alternate between
forms of
protection. While a chin guard and a visor are movable, the main portion of
the helmet covering
the side, top and back of the head is largely fixed in size and/or shape.
[0006] WO 2019/076689 describes a helmet with an outer shell and an inner
shell, where the
inner shell is able to slide relative to the outer shell. The inner shell is
also made in segments,
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so that the segments can slide relative to the outer shell somewhat
independently of one another.
Such a design is designed to protect the user from tangential components of
impact as well as
from radial impact. However, the outer shell does not allow for flexibility of
the helmet shape.
[0007] US 2015/0320134 describes a lightweight protective headgear for non-
contact sports
comprising a soft foam helmet designed to prevent head and facial injuries to
the user. Whilst
this is lightweight and flexible, this provides minimal protection and is
therefore not suitable
for many applications.
Summary of the Present Invention
[0008] According to one aspect of the invention, there is provided an impact
protection system
for wearing on a head of a user, the impact protection system comprising a
protective layer
formed from a plurality of panels, wherein at least one of the panels can
translate relative to
one or more of the other panels a sufficient amount to facilitate a change in
the shape of the
protective layer.
[0009] In an embodiment, the panels are flexible.
[0010] In an embodiment, at least some of the panels that are adjacent
partially overlap.
[0011] In an embodiment, the overlapping of the panels comprises a half lap
join.
[0012] In an embodiment, one of the panels comprises a notch and another one
of the panels
comprises a tab, such that the tab fits within the notch to locate the panels
in a neutral position.
[0013] In an embodiment, the impact protection system further comprises a
deformable layer
inside the protective layer so as to face a wearer in use.
[0014] In an embodiment, the deformable layer comprises a shear thickening or
non-
Newtonian component.
[0015] In an embodiment, the deformable layer comprises at least one of: a
shear thickening
foam; a shear thickening moulded foam; a polymer matrix comprising a shear
thickening
additive; a foam with non-Newtonian fluid filling; a non-Newtonian material; a
polyurethane
energy-absorbing material; and, a polyurethane material containing
Polyborodimethylsiloxane.
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100161 In an embodiment, the shear thickening or non-Newtonian component has a
thickness
that is at least one of: ¨5mm; <5mm; <20mm; >10mm; 5-20mm; 10-15mm; <30mm;
and,
¨30mm;
[0017] In an embodiment, the deformable layer is made of at least one of: an
auxetic material;
a deformable fluid layer; an impact absorbing foam; an elastically deformable
layer; a
plastically deformable layer; a plastic; a rubber; Kevlar; an EPU (Expanded
PolyUrethane)
foam; an EPS (Expanded Polystyrene) foam; an EPP (Expanded Polypropylene)
foam; and, a
PPS (Polyphenylene Sulfide) foam.
[0018] In an embodiment, the deformable layer and the protective layer are at
least partially
coupled using at least one of: mechanical bonding; chemical bonding; welding;
adhesive; and,
fasteners.
[0019] In an embodiment, the deformable layer is removable.
[0020] In an embodiment, the deformable layer has a thickness that is at least
one of: ¨15mm;
>20mm; >23mm; <26mm; <30mm; 20-25mm; 23-26mm; and, ¨30mm; and, the protective
layer has a thickness that is at least one of: ¨1mm; >lmm; >1.5mm; <3mm; <4mm;
1-4mm;
1.5-3mm; and, ¨4mm.
[0021] In an embodiment, the deformable layer comprises a plurality of
sections that are each
attached to a single one of the panels.
[0022] In an embodiment, the plurality of sections of the deformable layer
comprise chamfered
edges to accommodate the translation of the panels.
[0023] In an embodiment, a flexible member extends downwardly from a lower
edge of a rear
portion of the deformable layer.
[0024] In an embodiment, the flexible member is configured to abut and
substantially conform
to a shape of a user's head and/or neck during use.
[0025] In an embodiment, the deformable layer has a cover extending over an
inner surface so
as to be located between the deformable layer and the head of the user during
use, the cover
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being made of at least one of: a woven fabric; a non-woven fabric; an
elasticated fabric; and,
an open cell foam.
[0026] In an embodiment, the protective layer has a cover extending over an
outer surface, the
cover being made of at least one of: a woven fabric; a non-woven fabric; an
elasticated fabric;
and, an open cell foam.
[0027] In an embodiment, the panels are connected to one another to limit a
width of a gap that
can form when adjacent panels translate away from one another.
[0028] In an embodiment, the panels are connected by at least one of: an
elastic tether; an
inelastic strap; a flexible band; and, a rigid brace.
[0029] In an embodiment, the protective layer comprises at least one backing
member that
spans the gap caused when the panels translate away from one another.
[0030] In an embodiment, the backing member comprises at least one groove and
the panels
on either side of the backing member comprise at least one pin that extends
into the groove,
the pins and groove thereby cooperating to allow but also limit relative
translation between the
panels that are connected by the backing member.
[0031] In an embodiment, the relative translation between the panels can occur
in three
dimensions.
[0032] In an embodiment, one of the panels is a central spine that is
flexible.
[0033] In an embodiment, the central spine runs coronally.
[0034] In an embodiment, the central spine runs sagitally.
[0035] In an embodiment, a plurality of the panels are anchored to the central
spine.
[0036] In an embodiment, the central spine has a bias towards extension.
[0037] In an embodiment, the central spine has a bias towards flexion.
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100381 In an embodiment, the central spine comprises a biasing member that is
coupled to an
inside surface of the central spine.
[0039] In an embodiment, the central spine comprises a biasing member that is
coupled to an
outside surface of the central spine.
[0040] In an embodiment, the biasing member extends through one or more
apertures in the
central spine, thereby securing the biasing member to the outer surface while
allowing the
biasing member to slide relative to the central spine during bending.
[0041] In an embodiment, ends of the biasing member extend through apertures
in the central
spine, such that as the central spine bends the biasing member is free to
slide relative to the
central spine while remaining substantially abutting the outer surface.
[0042] In an embodiment, the protective layer is coupled to a securing
mechanism to secure
the impact protection system to the user.
[0043] In an embodiment, the protective layer is made of at least one of: a
thermoplastic
polymer; ABS (Acrylonitrile Butadiene Styrene); PP (Polypropylene); PC
(Polycarbonate);
Kevlar; and, HDPE (High-density polyethylene).
[0044] In an embodiment, the protective layer comprises at least one of: a
honeycomb
structure; one or more holes that allow airflow therethrough; surface features
that enhance
localised flexibility; variable thickness; and, ribbing.
[0045] In an embodiment, the impact protection system comprises a visual
indicator indicative
of a damage state of the impact protection system.
[0046] In an embodiment, the visual indicator undergoes a colour change
following an impact
with the impact protection system.
[0047] In an embodiment, the impact protection system comprises an adjustment
mechanism
to at least partially adjust the size of the impact protection system.
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100481 In an embodiment, the adjustment mechanism comprises: one or more
tensioning
members; an elasticated tensioning system; a ratchet tensioning system; and,
an adjustable
internal frame.
[0049] In an embodiment, the impact protection system can be folded or
squashed for storage.
[0050] In an embodiment, the width of the impact protection system when folded
relative to
the width in a neutral position is reduced by at least one of: 40%; 50%; 60%;
and, 70%.
[0051] It will be appreciated that the broad forms of the invention and their
respective features
can be used in conjunction and/or independently, and reference to separate
broad forms is not
intended to be limiting. Furthermore, it will be appreciated that features of
the method can be
performed using the system or apparatus and that features of the system or
apparatus can be
implemented using the method.
Brief Description of the Drawings
[0052] Various examples and embodiments of the present invention will now be
described
with reference to the accompanying drawings, in which: -
[0053] Figure 1 is a front left angled view of an impact protection system
according to an
embodiment of the invention;
[0054] Figure 2 is a front view of the impact protection system from Figure 1;
[0055] Figure 3 is a left side view of the impact protection system from
Figure 1;
[0056] Figure 4 is a rear view of the impact protection system from Figure 1;
[0057] Figure 5 is a bottom view of the impact protection system from Figure
1;
[0058] Figure 6 is a top view of the impact protection system from Figure 1;
[0059] Figure 7 is a bottom right angled view of the impact protection system
from Figure 1
with a deformable layer removed;
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100601 Figure 8 is an upper rear right angled view of the impact protection
system from Figure
1;
[0061] Figure 9 is an enlarged view of an edge of a panel from the impact
protection system
from Figure 1;
[0062] Figure 10 is a side view of another embodiment of the impact protection
system in a
collapsed position;
[0063] Figure 11 is a rear view of the impact protection system from Figure 10
in a neutral
position;
[0064] Figure 12 is a rear view of the impact protection system from Figure 10
in the collapsed
position;
[0065] Figure 13 is an upper front right angled view of another embodiment of
the impact
protection system;
[0066] Figure 14 is a side view of the impact protection system from Figure
13;
[0067] Figure 15 is a bottom view of the impact protection system from Figure
13;
[0068] Figure 16 is an enlarged bottom view of a portion of the impact
protection system from
Figure 13 with a neck padding partially removed;
[0069] Figure 17 is a top view of the neck padding that optionally forms part
of the impact
protection system;
[0070] Figure 18 is a side view of the impact protection system from Figure 13
with an
alternative form of neck padding;
[0071] Figure 19 is lower front left angled view of another embodiment of the
impact
protection system; and
[0072] Figure 20 is an enlarged portion of Figure 19 as identified by Detail
A.
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Detailed Description of the Preferred Embodiments
[0073] An example of an impact protection system in accordance with an
embodiment of the
invention will now be described.
[0074] In this example, the impact protection system is suitable for wearing
on a head of a user
and has a protective layer formed from a plurality of panels. At least one of
the panels can
translate relative to one or more of the other panels a sufficient amount to
facilitate a change in
the shape of the protective layer.
[0075] Such a system is advantageous because it can adapt to allow the impact
protection
system to accommodate a variety of head shapes and sizes. This in turn makes
the system more
comfortable for the user, as well as potentially making a single design and/or
size suitable for
a wider range of users.
[0076] Typically, the outer shell of a traditional helmet would be made to be
larger than
required, with foam padding pieces of various sizes being provided to "pad
out" the helmet to
fit the particular user. This results in the overall size of the helmet being
much larger than the
user's head, creating a bulky appearance. In an attempt to address this issue,
the helmet may
be provided in a large number of sizes, but the user would still often need a
slightly larger size
to accommodate their particular head shape. As such, by providing a system
that can change
shape, this bulky appearance can be greatly reduced because the system adapts
to the shape of
the user's head.
[0077] Additionally, the impact protection system may have a sufficient range
of shapes to
allow the system to be collapsed, folded, squashed, or otherwise adapted to
occupy a smaller
or more convenient shape for transport when not in use. For example, the
change in shape may
allow the impact protection system to be more easily packed into luggage.
Similarly, the ability
to change shape may prevent damage to the impact protection system in these or
other similar
situations.
[0078] A number of further example features will now be described.
[0079] In some examples of the impact protection system, the panels may be
flexible. This can
allow the system to take an even wider range of shapes and/or may make the
system more
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resilient to damage when not being worn. For example, if the impact protection
system was to
be squashed when packed in luggage, it may be able to bend to absorb the
force, as opposed to
a traditional helmet that may crack, for example. In some examples, the width
of the impact
protection system may be reduced by 40%, 50%, 60%, or even potentially 70% or
more,
without any permanent damage.
[0080] The impact protection system may be designed so that at least some of
the panels that
are adjacent partially overlap. By doing so, this can allow the adjacent
panels to translate
relative to one another without creating a gap between the panels. Depending
on the specific
design, this may be for all or only a portion of the relative movement. In any
event, preventing
a gap from forming, or at least limiting the size of the gap, is advantageous
because such a gap
could potentially allow a sharp object to penetrate the protection system more
easily.
[0081] The overlapping of the panels may be achieved by any of a range of
means, such as a
lap join, a half lap join, or tapered edges of the panels. The half lap join
and tapered edges are
both advantageous because they allow the overlapping to occur without an
increase in the
overall thickness of the protective layer. They also limit the possibility of
the panels catching
as they move toward one another after being separated. The half lap join may
also be
advantageous in some situations because it creates a stop point to limit the
amount that the
panels will overlap.
[0082] Where adjacent panels meet, one of the panels may also be provided with
a notch or
other similar cutout, while the adjoining panel has a tab or other similar
protrusion to match
the cutout. In this way, the tab fits within the notch to locate the panels in
a neutral position.
That is, the panels may be pulled apart from one another, but when moved back
together again
the tab and the notch guide the panels into their preferred location.
[0083] These features may also be used to constrain the direction of the
relative translation of
the panels. In particular, the notch and tab may prevent relative movement
that is parallel to
the adjoining edges while allowing translation that is normal to the edges.
[0084] In some embodiments, the impact protection system may have a deformable
layer inside
the protective layer so as to face a wearer in use. This deformable layer may
be made from or
at least include any of a range of materials, such as but not limited to an
impact absorbing foam,
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an elastically deformable layer, a plastically deformable layer, a plastic, a
rubber, an auxetic
material, a deformable fluid layer, Kevlar, an EPU (Expanded PolyUrethane)
foam, an EPS
(Expanded Polystyrene) foam, an EPP (Expanded Polypropylene) foam, and a PPS
(Polyphenylene Sulfide) foam.
[0085] By providing a deformable layer inside the protective layer in this
way, a broader range
of impact types may be protected against. For example, the protective layer
may protect against
penetration by a sharp object, while the deformable layer is more effective at
absorbing and
distributing the energy of a blunt force.
[0086] In these or other embodiments, the deformable layer may have a shear
thickening or
non-Newtonian component. For example, the deformable layer may include
materials such as,
but not limited to, a shear thickening foam, a shear thickening moulded foam,
a polymer matrix
with a shear thickening additive, a foam with non-Newtonian fluid filling, a
non-Newtonian
material, a polyurethane energy-absorbing material, and a polyurethane
material containing
Polyborodimethylsiloxane.
[0087] Providing a shear thickening or non-Newtonian component in the
deformable layer is
particularly advantageous because it may provide an improved comfort level
during normal
use and/or improving the protection against an impact. The ability of the
material to have
different properties when a force is applied may allow it to achieve these
seemingly competing
requirements.
[0088] In one example, the shear thickening or non-Newtonian component has a
thickness that
is approximately 5mm. In other examples, this component may have a thickness
less than 5mm,
less than 20mm, greater than 1 Omm, between 5 and 20mm, between 10 and 15mm,
less than
30mm, or approximately 30mm.
[0089] The deformable layer and the protective layer may be at least partially
coupled using a
range of methods, such as but not limited to mechanical bonding, chemical
bonding, welding,
adhesive, and fasteners. The deformable layer may be removable, such as if the
coupling uses
a hook and loop fastener or press studs, for example.
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100901 In one example, the deformable layer has a thickness that is
approximately 15mm;
greater than 20mm, greater than 23mm, less than 26mm, less than 30mm, between
20 and
25mm, between 23 and 26mm, or approximately 30mm. Most typically, the
thickness will be
approximately 23mm to 26mm, depending on the specific shape chosen. The
protective layer
may have a thickness of approximately lmm, greater than lmm, greater than
1.5mm, less than
3mm, less than 4mm, between 1 and 4mm, between 1.5 and 3mm, or about 4mm. A
thinner
lightweight arrangement is most preferred, with the thickness typically in the
range of
approximately 1.5mm to 3mm.
[0091] Typically, the deformable layer can be formed as a plurality of
sections that are each
attached to a single one of the panels. These sections may be completely
independent, or may
be partially coupled or linked in some way. By providing the deformable layer
in this way, it
allows the panels to translate relative to one another without any impediment
from the
deformable layer. The sections of the deformable layer may also have chamfered
edges to
accommodate the translation of the panels without causing interference.
[0092] In some embodiments, the deformable layer may have a cover extending
over an inner
surface, so that it abuts the head of the user during use. This cover can be
made of any suitable
material, such as but not limited to a woven fabric, a non-woven fabric, an
elasticated fabric,
and an open cell foam. For example, in one preferred form, the cover may be a
knitted wool or
synthetic material, most preferably merino wool.
[0093] In some embodiments, the protective layer may have a cover extending
over an outer
surface. This cover can be made of any suitable material, such as but not
limited to a woven
fabric, a non-woven fabric, an elasticated fabric, and an open cell foam. For
example, in one
preferred form, the cover may be a knitted wool or synthetic material, most
preferably a
polyester/acrylic fabric, giving the appearance of a "beanie" or "knit cap".
[0094] In this way, the impact protection system can potentially have an
appearance that may
be considered more attractive than a traditional helmet while still providing
similar protective
benefits. The ability of the impact protection system to change shape can also
assist with
imitating a beanie, because the system will better conform to the shape of the
user's head in
much the same way that a beanie does.
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[0095] In some embodiments, a flexible member may extend downwardly from a
lower edge
of a rear portion of the deformable layer. The flexible member may be
configured to abut and
substantially conform to a shape of a user's head and/or neck during use. For
example, it may
conform to the user's head shape, particularly in the region of the occipital
bone, which could
improve the fit and feel of the impact protection system.
[0096] In some optional embodiments of the impact protection system, the
panels are
connected to one another to limit a width of a gap that can form when adjacent
panels translate
away from one another. For example, adjacent panels may be connected by an
elastic tether,
an inelastic strap, a flexible band, a rigid brace, or some other form of
coupler that allows the
panels to move apart only to a point where they are then constrained from
moving any further
apart. This connection means may involve a hard limit where the panels are
free to move before
being stopped, or be a more gradual limit where a resisting force gradually
increases with the
distance.
[0097] In one example, the protective layer may include at least one backing
member that spans
the gap caused when the panels translate away from one another. Such a backing
member
addresses the issue raised previously, where a gap between the panels may also
sacrifice safety
because sharp objects can penetrate the gap. Instead, the backing member can
allow the panels
to move apart enough that a gap forms, while maintaining a complete cover for
penetration
resistance.
[0098] In one specific example, the backing member may have a groove and the
panels on
either side of the backing member have at least one pin that extends into the
groove. The pins
and groove cooperate to allow but also limit relative translation between the
panels that are
connected by the backing member. The backing member may extend along a join
between
panels with a series of grooves and respective pins to couple with each
groove.
[0099] This design of backing member is advantageous because it allows free
movement
between the panels until the hard limit is reached when the pins reach the
ends of the groove.
If it is desirable to have resistance to the panels moving apart, however, an
elastic tether or
other similar device could be used in conjunction with the backing member.
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[0100] In some embodiment, the relative translation between the panels can
occur in three
dimensions. That is, the panels can preferably translate within a plane of the
panels both normal
to the edge and along the edge, as well as in a direction normal to the plane
of the panels. In
other embodiments, however, the relative translation may occur in only two or
even one
dimension. For example, the panels may be restricted from relative translation
outside the plane
of the panels. In other examples, this direction may be possible but they may
not be able to
translate in a direction parallel to the edge. In yet other examples, they may
be restricted to
only translating in the direction within the plane and normal to the edge.
[0101] In some example embodiments of the impact protection system, one of
the panels
may be a central spine that is flexible. In various alternative embodiments,
the central spine
may run coronally (from ear to ear), while in other alternative embodiments
the central spine
may run sagittally (from front to back).
[0102] In one such embodiment, a plurality of the panels may be anchored to
the central
spine. For example, the central spine may extend from the front to the back of
the impact
protection system, with each of the remaining panels extending from the
central spine and being
anchored thereto. This anchoring may use any suitable fastening means, such as
but not limited
to a clip, a fastener, or an adhesive.
[0103] In some optional embodiments, the central spine may play a role in
forming the
shape of the impact protection system and/or assisting to maintain a
comfortable fit of the
system. In some cases, this could be achieved by the central spine having a
bias towards
extension, while in others it could be achieved by the central spine having a
bias towards
flexion.
[0104] For example, if the central spine has a bias towards extension, this
means that the
central spine will have a tendency towards lying flat, rather than being
curved. If the central
spine runs sagittally, then this will cause the front and the back of the
impact protection system
to move apart, resulting in the sides moving inwardly. This can cause the
impact protection
system to have a collapsed or "squashed" shape when not being worn, and can
cause the sides
to "hug" the head of the user when being worn. This in turn may create an
improved and/or
more secure fit, or at least provide such a perception to the user.
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[0105] In some of these embodiment, the bias of the central spine may be
achieved using
a biasing member that is coupled to an outside surface or an inside surface of
the central spine.
This biasing member may be a resiliently deformable member made from any
suitable material,
such as but not limited to plastic, metal, carbon fibre, or another composite
material.
[0106] In one example, the biasing member may extend through one or more
apertures in
the central spine, thereby securing the biasing member to the outer surface
while allowing the
biasing member to slide relative to the central spine during bending. That is,
the aperture
provides a mechanical means of coupling the biasing member to the central
spine while still
allowing enough relative movement as will be necessary through the range of
motion of the
central spine.
[0107] Similarly, the ends of the biasing member may extend through
apertures in the
central spine, so that as the central spine bends the biasing member is free
to slide relative to
the central spine while remaining substantially abutting the outer surface.
Otherwise stated, as
the central spine bends the biasing member will also bend with it, but because
it is located
against an outer surface the overall length required will change due to the
changing radius.
Therefore, as the central spine extends the biasing member can move further
into the apertures
and as the central spine flexes the biasing member cam move back out of the
apertures. Thus,
the biasing member can accommodate the changing radius of the central spine
without causing
any restriction.
[0108] In some embodiments, the protective layer may be coupled to a
securing
mechanism to secure the impact protection system to the user. For example, a
strap with a
buckle may be connected to two or more locations on the protective layer, so
that the strap can
pass under the chin of the user and secure the system in place. It will be
appreciated, however,
that various alternative securing mechanisms could also be used, as will be
known to those
skilled in the art.
[0109] The protective layer can be made of any suitable material or
combination of
materials as will be appropriate for the particular design and intended use.
These materials
could include, but are not limited to, at least one of a thermoplastic
polymer, ABS
(Acrylonitrile Butadiene Styrene), PP (Polypropylene), PC (Polycarbonate),
Kevlar, and
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HDPE (High-density polyethylene). Preferably, the material will be resistant
to penetration by
a sharp object, while still having at least some degree of flexibility. The
material will also
preferably be lightweight and able to perform adequately while being as thin
as possible.
[0110] The protective layer may also optionally include one of a variety of
other features
to aid in strength, comfort or performance, such as a honeycomb structure, one
or more holes
that allow airflow therethrough, surface features that enhance localised
flexibility, variable
thickness, ribbing, and/or any other features as may be known to those skilled
in the art.
[0111] The impact protection system may also have a visual indicator
indicative of a
damage state of the impact protection system. For example, the visual
indicator could undergo
a colour change following an impact with the impact protection system. Such an
indicator
would be advantageous for simple identification of situations when the impact
protection
system requires repair or replacement, which otherwise may not be obvious or
even possible
to tell without the use of sophisticated testing equipment.
[0112] The impact protection system may also have an adjustment mechanism
to at least
partially adjust the size of the impact protection system. For example, the
adjustment
mechanism could have one or more tensioning members, an elasticated tensioning
system, a
ratchet tensioning system, an adjustable internal frame, and/or any other
suitable mechanism
as may be known to those skilled in the art.
[0113] An example of a preferred embodiment of the invention will now be
described with
reference to Figures 1 to 9.
[0114] Referring to Figure 1, an impact protection system in the form of a
helmet 100 is
shown. The helmet 100 has a protective layer 101 towards the outside and a
deformable layer
102 towards the inside facing a user's head during use.
[0115] The protective layer 101 is made up of panels 104 that are connected
to a central
spine 105. The central spine 105 has a biasing member 106 extending along an
outer surface
thereof
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[0116] Referring to Figure 3, the panels 104 can be seen in more detail,
together with
anchor points 108 for securing a strap or other similar device for securing
the helmet 100 to
the user. There are three panels 104 along each side of the helmet 100, each
connected to the
central spine 106 and one or more adjacent panels 104.
[0117] The joins 110 between adjacent panels 104 are also shown in Figure
3. It can be
seen that some panels 104 include a tab 111 that couples with a notch in the
adjacent panel.
The notch and tab 111 ensure that the panels are correctly located when
returned to a neutral
position after being separated.
[0118] Figure 9 shows the edge of a panel 104 in more detail, including the
tab 111. It also
shows that the panels have a cutout to create a half-thickness section 112
that couples with a
reverse half-thickness section on the adjacent panel 104. Together, these thin
sections create a
half lap join between the adjacent panels 104. That is, the thin sections
overlap to create an
overlapping section that has a thickness no greater than the typical thickness
of either panel.
[0119] Referring now to Figure 7, the inside of the joins 110 between
panels 104 is shown
with the deformable layer 102 removed for clarity. A backing member 115 spans
the join 110
and is attached to each panel 104 using pins 116 extending from the panels 104
through grooves
117 in the backing member 115. A clip 118 at an upper end of the backing
member 115 anchors
the backing member 115 to the central spine 105. The panels 104 are also
anchored to the
central spine 105 by clips 120.
[0120] It will be clear that the joins 110 between adjacent panels 104
allow a degree of
separation. That is, the panels 104 can be pulled apart from one another, with
the pins 116
sliding along the grooves 117 in the backing member 115 to allow this to
occur. For an initial
part of this movement, the half-thickness sections 112 will still be partially
overlapping to
prevent any gap forming. Towards the end of the movement, however, a gap may
form between
the panels 104. Despite this, the backing member still provides a level of
protection from
penetration of an external object through the gap.
[0121] The join between the panels 104 and the central spine 105 cannot be
pulled apart
in this manner, however a degree of pivot and/or bending can occur to allow
the relative
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movement between panels 104. It will be appreciated, however, that a similar
join and backing
member could be provided at this location in an alternative embodiment.
[0122] The end result is a helmet 100 that facilitates a change of shape.
For example, the
sides of the helmet 100 can be pushed inwardly, allowing the helmet 100 to be
"squashed".
This is accommodated by necessary parts of the joins 110 between the panels
104 pulling apart
from one another. That is, the join 110 does not necessarily need to separate
evenly along the
length, but rather may separate more at one location than another, depending
on the desired
change in shape of the helmet 100. It is also possible for the panels 104 to
translate relative to
one another in three dimensions when necessary, such as by part of a panel 104
being raised
above or outside the plane of the panels 104, while another part of the join
110 is pulled apart
within the plane.
[0123] The change in shape of the helmet 100 is also assisted by the panels
104 having
some flexibility. In the embodiment being described, the panels 104 would
typically be made
from a high density polyethylene (HDPE) that is tough and resistant to
penetration while also
being somewhat flexible, but it will be appreciated that many other materials
could
alternatively be used.
[0124] Referring to Figure 8, the central spine 105 can be seen in some
detail. The biasing
member 106 abuts an outer surface of the central spine 105 and is held against
the central spine
105 by a bridge 122 under which the biasing member 106 passes. A raised
section 123 towards
each end also creates an aperture into which the biasing member 106 enters,
thereby also
holding the ends of the biasing member 106 against the central spine 105.
[0125] The biasing member 106 has a natural shape that is closer to flat
than the curved
shape as shown in the Figures. Accordingly, the biasing member 106 provides a
force in an
outward direction at the ends thereof That is, the biasing member 106 has a
tendency towards
extension. As the helmet 100 is able to change shape as described previously,
the biasing
member 106 has the effect of causing the front and rear parts of the helmet
100 to move
outwardly and the sides to move inwardly.
[0126] As the shape of the helmet 100 changes, the biasing member 106 is
able to slide
relative to the central spine 105 to accommodate this movement. The biasing
member 106 may
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be fixed at the bridge 122, but can slide further in or out of the raised
sections 123 at each end
as necessary.
[0127] Referring to Figure 5, the deformable layer is shown in more detail.
Here it can be
seen that the deformable layer is made up of individual foam pads 102, each
attached to a
different one of the panels 104. They are held in place using a hook and loop
fastener, but it
will be appreciated that other securing mechanisms could alternatively be
used. The edges of
the foam pads 102 are chamfered to create gaps between the pads 102, ensuring
that there is no
interference as the panels 104 translate relative to one another, such as when
the helmet 100 is
folded, for example.
[0128] While not shown in the Figures, the helmet 100 would preferably be
provided with
an outer cover, which may be fabric or another soft material. A knitted wool
cover, for example,
would typically be used in embodiments of the helmet 100 intended for snow
sports. This
would give the appearance of a beanie, while still having the necessary
protective properties.
The ability of the helmet 100 to change shape would also further assist in
achieving the
"beanie" appearance.
[0129] An alternative example of an embodiment of the invention is shown in
Figures 10
to 12. Referring to Figure 10, the relative movement of adjacent panels 204 of
the helmet 200
when in the collapsed position can be more clearly seen. At a lower end of the
join 210, a
significant gap is seen between the panels 204. Toward an upper end of the
join 204, however,
there is no gap of even additional overlap in comparison to the neutral
position.
[0130] Figures 11 and 12 illustrate the ability of the helmet 200 to be
collapsed or
squashed. Figure 11 shows the helmet 200 in a neutral position as taken when
there are no
external forces being applied, while Figure 12 shows that the helmet 200 is
collapsed with
relatively little inward pressure when the helmet 200 is not being worn.
[0131] Yet another embodiment of the invention is shown in Figures 13 to
17. Referring
in particular to Figures 13 to 15, an optional neck padding 330 is fitted to
the helmet 300. In
use, the neck padding 330 extends downwardly from the rear of the helmet 300
and contacts
the back of the user's neck, providing additional warmth and/or comfort, and
potentially
providing a fit with a more secure feel.
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[0132] The neck padding 330 is a piece of foam that is shaped to fit around
the occipital
bone at the rear of the user's head. It extends beyond a typical helmet line,
and can provide
extra fastening around the occipital protuberance. The neck padding 330 is
also shaped in a
way that cups around the top of the user's ears to complete the feel and to
help locate the piece.
The neck padding 330 is made of a mid-firmness foam that has enough
flexibility to be able to
be pulled in around the head, but also is firm enough to make it feel like a
solid piece around
the back of the head. It will be appreciated that alternative materials and/or
firmness of the
foam could be used, however, or options potentially even provided to the user.
[0133] This addition to the helmet 300 also allows the helmet 300 to more
closely imitate
the look and feel of a beanie, as this more closely represents the position
that a beanie would
sit on the user's neck.
[0134] An outer sock 332 of the neck padding 330 extends around the
perimeter of the
protective layer 301 of the helmet 300, with a web 333 extending over the top
of the panels
304. The sock 332 and web 333 are made from neoprene, but it will be
appreciated that
alternative materials could be used. Importantly, the material should be
flexible and have
sufficient elasticity, as it is responsible for the articulating and
conforming to the back of the
head.
[0135] As shown in Figure 15, the neck padding 330 itself extends
downwardly from the
deformable layer 302, effectively forming an extension of the deformable layer
302. Figure 16
shows that the deformable layer 302 has hook and loop fasteners 335 attached
to assist with
securing the neck padding 330 in position.
[0136] In Figure 17, the neck padding 330 itself is shown separated from
the deformable
layer 302 and the outer sock 332. Cutouts 336 are visible, which are provided
to conform to
the user's ears. Meanwhile, Figure 18 shows a different design of neck padding
340, where the
outer sock 332 and web 333 are not required.
[0137] Referring to Figure 16, the deformable layer is shown in more
detail. Here it can
be seen that the deformable layer is made up of individual pads 302, each
attached to a different
one of the panels 304. In this embodiment, the pads 302 are made from a non-
Newtonian foam
with Polyurethane inserts 350.
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[0138] Figures 19 and 20 shown another embodiment of a helmet 400. In this
embodiment,
holes 445 are provided in the deformable layer 402 to house inserts in the
deformable layer
402, which is made from a shear thickening or non-Newtonian material.
[0139] In the foregoing description of preferred embodiments, specific
terminology has
been resorted to for the sake of clarity. However, the invention is not
intended to be limited to
the specific terms so selected, and it is to be understood that each specific
term includes all
technical equivalents which operate in a similar manner to accomplish a
similar technical
purpose. Terms such as "front" and "rear", "inner" and "outer", "above" and
"below" and the
like are used as words of convenience to provide reference points and are not
to be construed
as limiting terms
[0140] Throughout this specification and claims which follow, unless the
context requires
otherwise, the word "comprise", and variations such as "comprises" or
"comprising", will be
understood to imply the inclusion of a stated integer or group of integers or
steps but not the
exclusion of any other integer or group of integers. As used herein and unless
otherwise stated,
the term "approximately" means 20%.
[0141] It must be noted that, as used in the specification and the appended
claims, the
singular forms "a," "an," and "the" include plural referents unless the
context clearly dictates
otherwise. Thus, for example, reference to "a support" includes a plurality of
supports. In this
specification and in the claims that follow, reference will be made to a
number of terms that
shall be defined to have the following meanings unless a contrary intention is
apparent.
[0142] Persons skilled in the art will appreciate that numerous variations
and
modifications will become apparent. All such variations and modifications
which become
apparent to persons skilled in the art, should be considered to fall within
the spirit and scope
that the invention broadly appearing before described.
