Note: Descriptions are shown in the official language in which they were submitted.
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CUSHION PADS AND RELATED SYSTEMS
TECHNICAL FIELD
[001] The technical field generally relates to protective gear and
equipment, and more
specifically relates to a helmet provided with a liner made of cushion pads.
BACKGROUND
[002] Contact sports, and more specifically multi-contact sports, generally
involve
collisions and, in some cases, repeated collisions. Non!imitative examples of
multi-contact
sports include American football and hockey. Repeated collisions, especially
proximate
the head, the neck and/or the shoulder regions can result in serious injuries.
While helmets
and other protective gear and applications for the body and/or items have
evolved greatly
over the years in an attempt to provide optimum protection, there is still a
general need for
improvements.
SUMMARY
[003] According to an aspect, a cushion pad connectable to a garment for
providing
protection thereto is provided. The cushion pad includes a plurality of layers
formed of
strings disposed in a manner to define a repeating pattern, with the plurality
of layers being
stacked on one another to define one or more cells along a thickness of the
cushion pad.
[004] According to a possible embodiment, the repeating pattern is defined
in each
layer of the plurality of layers.
[005] According to a possible embodiment, the repeating pattern is defined
by at least
two adjacent layers of the plurality of layers.
[006] According to a possible embodiment, the repeating pattern includes a
lattice
pattern, a honeycomb pattern, a hexagonal pattern or a combination thereof.
[007] According to a possible embodiment, the plurality of layers comprises
a first
section and a second section, and wherein the strings of the first section of
the plurality of
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layers define a first repeating pattern, and the strings of the second section
of the plurality
of layers define a second repeating pattern.
[008] According to a possible embodiment, the first repeating pattern and
the second
repeating pattern are configured to provide respective impact absorption
behaviors.
[009] According to a possible embodiment, the first section and the second
section are
stacked one on top of another.
[0010] According to a possible embodiment, the strings of the first section
define the
lattice pattern, and the strings of the second section define the honeycomb
pattern.
[0011] According to a possible embodiment, at least some of the one or more
cells are
shaped and configured to reversibly deform.
[0012] According to a possible embodiment, the strings of at least some of the
plurality
of layers are aligned with the strings of another one of the plurality of
layers to form
substantially straight cells.
[0013] According to a possible embodiment, the strings of at least some of the
plurality
of layers are offset relative to the strings of one or more adjacent layers.
[0014] According to a possible embodiment, the strings of at least some of the
plurality
of layers are axially offset in at least one direction relative to the strings
of one or more
adjacent layers, rotationally offset relative to the strings of one or more
adjacent layers, or
a combination thereof.
[0015] According to a possible embodiment, the strings of at least some of the
plurality
of layers are rotationally offset by between about 1 degree and 359 degrees
relative to the
strings of one or more adjacent layers.
[0016] According to a possible embodiment, at least some of the plurality of
layers are
substantially planar and parallel to one another.
[0017] According to a possible embodiment, at least some of the plurality of
layers are
substantially planar and angled relative to one another.
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[0018] According to a possible embodiment, at least some of the plurality of
layers are
non-planar.
[0019] According to another aspect, a helmet is provided. The helmet includes
an outer
shell defining a cavity for receiving a head of a person; a support structure
coupled to the
outer shell and positioned within the cavity, the support structure comprising
a web of
support material positioned in a spaced-apart relation relative to the outer
shell and
defining a plurality of openings; and a plurality of cushion pads provided
within respective
openings of the web of support material, the plurality of cushion pads forming
a liner of the
helmet, where each cushion pad comprises an outer cushion section extending
between
the outer shell and the web of support material and an inner cushion section
extending
within the cavity on an opposite side of the web of support material relative
to the outer
cushion section.
[0020] According to a possible embodiment, the cushion pads are manufactured
using
an additive manufacturing process.
[0021] According to a possible embodiment, the cushion pads are manufactured
using
a 3D printing process.
[0022] According to another aspect, a protective garment having a surface
provided with
a support structure is provided. The protective garment includes a plurality
of cushion pads
connectable to the support structure and adapted to form a liner of the
protective garment,
each cushion pad comprising an outer cushion section extending between the
surface of
the protective garment and support structure, and an inner cushion section
extending
opposite the outer cushion section on an opposite side of the support
structure.
[0023] According to a possible embodiment, each cushion pad comprises a
plurality of
layers formed of segments defining a repeating pattern, and wherein the
plurality of layers
are stacked to define cells along a thickness of the cushion pad.
[0024] According to a possible embodiment, the repeating pattern is defined in
each
layer of the plurality of layers.
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[0025] According to a possible embodiment, the repeating pattern is defined by
at least
two adjacent layers of the plurality of layers.
[0026] According to a possible embodiment, the repeating pattern includes a
lattice
pattern, a honeycomb pattern, a hexagonal pattern or a combination thereof.
[0027] According to a possible embodiment, the plurality of layers comprises a
first
section and a second section, and wherein the segments of the first section of
the plurality
of layers define a first repeating pattern, and the segments of the second
section of the
plurality of layers define a second repeating pattern.
[0028] According to a possible embodiment, the first repeating pattern and the
second
repeating pattern are configured to provide respective impact absorption
behaviors.
[0029] According to a possible embodiment, the first section and the second
section are
stacked one on top of another.
[0030] According to a possible embodiment, the first section includes layers
defining the
lattice pattern, and the second section includes layers defining the honeycomb
pattern.
[0031] According to a possible embodiment, at least some of the one or more
cells are
shaped and configured to reversibly deform.
[0032] According to a possible embodiment, the segments of at least some of
the
plurality of layers are aligned with the segments of another one of the
plurality of layers to
form substantially straight cells.
[0033] According to a possible embodiment, the segments of at least some of
the
plurality of layers are offset relative to the segments of one or more
adjacent layers.
[0034] According to a possible embodiment, the segments of at least some of
the
plurality of layers are axially offset in at least one direction relative to
the segments of one
or more adjacent layers, rotationally offset relative to the segments of one
or more
adjacent layers, or a combination thereof.
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[0035] According to a possible embodiment, the segments of at least some of
the
plurality of layers are rotationally offset by between about 1 degree and 359
degrees
relative to the segments of one or more adjacent layers.
[0036] According to a possible embodiment, at least some of the plurality of
layers are
substantially planar and parallel to one another.
[0037] According to a possible embodiment, at least some of the plurality of
layers are
substantially planar and angled relative to one another.
[0038] According to a possible embodiment, at least some of the plurality of
layers are
non-planar.
[0039] According to a possible embodiment, the protective garment includes a
helmet.
[0040] According to another aspect, a protective cushion pad is provided. The
protective
cushion pad includes a plurality of layers formed of strings disposed to
define a repeating
pattern, with the plurality of layers being stacked on each other to define
one or more cells
along a thickness of the cushion pad.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] Figure 1 is a perspective view of a cushion pad according to an
embodiment.
[0042] Figure 1A is an enlarged view of a portion of the cushion pad shown in
Figure 1,
showing a plurality of layers stacked relative to one another, in accordance
with an
embodiment.
[0043] Figure 2 is a bottom perspective view of the cushion pad shown in
Figure 1.
[0044] Figure 3 is a top view of a section of the cushion pad, showing a
repeating lattice
pattern, according to an embodiment.
[0045] Figure 3A is an enlarged view of a portion of the lattice pattern shown
in Figure 3,
showing a cell according to an embodiment.
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[0046] Figure 4 is a top view of a section of the cushion pad, showing a
repeating
honeycomb pattern, according to an embodiment.
[0047] Figure 5 is a top view of the cushion pad, showing a first section
having the
repeating lattice pattern and a second section having the repeating honeycomb
pattern
stacked on one another, according to an embodiment.
[0048] Figure 6 is a perspective view of a helmet fitted on a head of a
person.
[0049] Figure 7 is a perspective view of a helmet having an inner liner formed
from a
plurality of cushion pads, according to an embodiment.
[0050] Figure 8 is a front view of the helmet shown in Figure 7.
[0051] Figure 9 is a sectional view of the helmet shown in Figure 8, showing a
plurality
of cushion pads provided along the inner surface of the helmet.
[0052] Figure 10 is a perspective view of a support structure adapted to hold
the plurality
of cushion pads within the helmet, according to an embodiment.
[0053] Figures 11 and 12 are front and side views of the support structure
shown in
Figure 10, showing support members extending from a web of material, according
to an
embodiment.
[0054] Figures 13 to 15 are possible embodiments of a position of the support
structure
relative to the cushion pads.
[0055] Figures 16 to 18 illustrate a possible embodiment of the different
configurations
of the cushion pads adapted to be inserted in a helmet.
[0056] Figure 19 to 21 are schematic representations of layers being formed
one on top
of another in a substantially planar manner, according to an embodiment.
[0057] Figures 22 and 23 are schematic representations of layers being formed
one on
top of another in a multi-planar manner, according to an embodiment.
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[0058] Figure 24 to 26 are schematic representations of layers being formed
one on top
of another in a substantially non-planar manner, according to an embodiment.
[0059] Figure 27 to 30 are representations of segments being disposed to form
layers in
different layering sequences according to possible embodiments.
DETAILED DESCRIPTION
[0060] As will be explained below in relation to various embodiments, the
present
disclosure describes devices, systems and methods for forming protective gear,
such as
padding for use in various equipment and/or systems. The padding can be used
as part
of a helmet to improve shock absorption, among other advantages.
[0061] More particularly, the present disclosure relates to a protective
helmet, and
corresponding parts, which includes a protective structure lining an inner
surface thereof
to provide protection to the head of the wearer. The protective structure can
include an
array of cushion pads designed to improve performance of the helmet, such as
increasing
shock absorption, for example, thereby reducing potential risks and injuries
to the wearer.
The helmet can further be provided with a coating provided on the exterior
surface of the
outer shell adapted to increase the friction coefficient between the helmet
and another
item contacting the helmet, such as a second helmet. For example, during a
football game,
helmets often contact, and slide off one another. It is noted that increasing
the friction
coefficient along the exterior surface of the helmets can reduce the sliding
motion, which
can in turn reduce the risk for injuries.
[0062] The protective structure (e.g., the cushion pads) can be positioned in
a
predetermined configuration within the helmet using a support structure
secured to the
inner surface of the helmet. The support structure can be shaped and adapted
to hold the
cushion pads in respective configurations along the interior of the helmet. In
some
implementations, the support structure includes a sling connectable to the
helmet shell in
a spaced-apart relation relative to the head of the wearer. The sling, and
corresponding
parts, define a plurality of apertures in which the cushion pads can be
positioned. The
cushion pads can include cushion sections having respective shapes, sizes,
configurations and/or properties. In some embodiments, the cushion pad
includes a pair
of cushion sections coupled to one another, or integrally formed together, to
form the
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cushion pad, which can be installed within an aperture of the sling for
positioning the
cushion pad within the helmet. As will be described further below, the cushion
sections
define an interface region therebetween shaped and adapted to cooperate with
the sling
to secure the cushion pad within the corresponding aperture of the sling.
[0063] At least one of the cushion sections of the cushion pads can be
manufactured
using digital fabrication techniques, which may include computer numerical
control (CNC)
and/or an additive manufacturing process, such as 3D printing, for example. As
mentioned
above, the cushion sections can include respective shapes, sizes,
configurations and/or
properties. For example, a cushion section can be formed of a plurality of
layers stacked
on one another, where each layer has a predetermined pattern, such as a
lattice pattern,
a honeycomb pattern, or any other suitable pattern(s) or combination thereof.
The layers
can be stacked substantially vertically and aligned relative to each other
such that the
structure of the cushion section is relatively uniform throughout a thickness
thereof. The
aligned layers can form the honeycomb configuration throughout the thickness
of the
cushion section, for example. Alternatively, or additionally, the layers can
be misaligned,
axially and/or rotationally, relative to one another. The misaligned layers
can be stacked
to form the lattice configuration throughout the thickness of the cushion
section, among
other possible configurations.
[0064] With reference to Figures 1 to 2, a cushion pad 10 according to a
possible
embodiment is illustrated. As will be described further below, the cushion pad
10 can be
integrated as part of various devices and/or systems to provide protection
(e.g., shock
absorbance) to the device, the system and/or the person(s) using or operating
the device
or system. The cushion pad 10 can have any suitable overall geometry and/or
size
adapted to provide protection. For example, in this embodiment, the cushion
pad 10 has
a cross-sectional shape having five (5) sides so as to form a generally
pentagonal shape
(see Figure 1). However, it is appreciated that the cushion pad 10 can have
any suitable
number of sides such as three (3) to form a triangular cross-sectional shape,
four (4) to
form a rectangular cross-sectional shape, etc. In some embodiments, the
cushion pad 10
tapers inwardly along its height (e.g., from a top end 12 to a bottom end 14
thereof) such
that the outer perimeter and the cross-sectional area of the cushion pad 10 is
smaller
proximate the bottom end relative to proximate the top end.
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[0065] In some embodiments, the cushion pad 10 can be manufactured using an
additive manufacturing process, which may include 3D printing and/or similar
techniques.
As used herein, it should be understood that the expression "additive
manufacturing"
refers to a manufacturing process where hardware is operated to deposit
material, layer
upon layer, in predetermined and/or desired geometric shapes. The hardware can
use
data from a computer-aided-design (CAD) software or one or more 3D object
scanners to
operate and form the desired object. It is noted that additive manufacturing
processes
adds material (e.g., layers) to create the object, such as the cushion pad 10.
It is also
noted that, by contrast, an object created by traditional means often requires
the removal
of material through milling, machining, carving, shaping and/or other means,
such as
injection moulding, compression moulding, etc.. The cushion pad 10 can be
created via
any suitable subset of additive manufacturing, such as via 3D printing or via
rapid
prototyping, for example. In some embodiments, the cushion pad 10 can be
further worked
on (e.g., polished) using non-additive manufacturing processes, such as those
listed
above.
[0066] The cushion pad 10 is created using relatively resilient material such
that forces
applied thereto can deform the cushion pad as it absorbs at least a portion of
those forces
to provide protection to the device, the system and/or the person(s) using or
operating the
device or system. Of note, the deformation of the cushion pad is generally
reversible. For
example, the cushion pad may be in a "deformed" or "compressed" configuration
when a
force is applied to the cushion pad or when energy is absorbed by the cushion
pad, and
the cushion pad may be in a "relaxed" or "original" configuration when no
force is applied
to the cushion pad or after the energy is released from the cushion pad. It
should also be
noted that the cushion pad described herein can be configured for single
impact
applications, where the pad deforms permanently to absorb forces/energy.
[0067] Still referring to Figures 1 to 2, and more specifically to Figure 1A,
the cushion
pad 10 includes a plurality of layers 20 successively bonded to an adjacent
layer 20 in
order to form the three-dimensional object, i.e., the cushion pad 10. Each
layer can have
substantially the same shape, although their size can vary. As described
above, each
subsequent layer can have a greater or smaller outer perimeter than a previous
layer while
keeping the same shape (e.g., the pentagonal shape seen in Figure 1). In some
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embodiments, each layer can be formed of relatively straight segments (e.g.,
strings or
cords of material), such as the outer perimeter 15 of the pentagonal shape of
the top
layer 16 seen in Figure 1. Alternatively, or additionally, one or more layers
20 can include
curved segments which can be adapted to form a recessed region of the formed
3D object.
For example, and as seen in Figures 1 and 2, the cushion pad 10 includes a
recessed
region 18 proximate the bottom end 14 thereof, where a plurality of adjacent
layers
includes a curved segment. It should be noted that the cushion pad 10 can
include straight
outer walls, sectioned outer walls, curved outer walls, or a combination
thereof. In some
embodiments, the recessed portion 18 (or at least a portion thereof) may be
conformal. In
some embodiments, the bottom end 14 may also be entirely or at least partially
conformal.
In some embodiments, the top end 12 may also be entirely or at least partially
conformal.
[0068] Although Figures 1 to 2 illustrate each layer 20 as a substantially
complete and
solid layer, it should be noted that each layer can include a specific
geometry defined
across the layer. With reference to Figures 3 to 5, in addition to Figures 1
to 2, in some
embodiments, each layer 20 can be formed with a repeating pattern across said
layer. For
example, one or more layers 20 can be formed with a lattice configuration
(seen in Figure
3) where a first set of segments 22 of a given layer are positioned parallel
to one another
across the layer, and where a second set of segments 24 of the same layer are
position
parallel to one another and perpendicularly relative to the first set of
segments 22 across
the layer. It is appreciated that the lattice configuration defines a
plurality of cells 30 across
the layer, where each cell 30 is formed from a pair of adjacent segments of
each set of
segments 22, 24. It is noted that each cell 30 of a given layer can have the
same
dimensions, for example, when the segments of each set of segments are
provided at
regular intervals across the layer. Alternatively, the segments can be
provided at irregular
intervals (e.g., larger and/or smaller intervals) across the layer such that
the cells 30 have
varying dimensions and shapes.
[0069] In some embodiments, each layer 20 may include a network of lines. In
some
embodiments, the network of lines may include a first set of spaced-apart
lines and a
second set of spaced-apart lines, and the first set and the second set of
spaced-apart lines
may be integrally formed. The first set and the second set of spaced-apart
lines may be
orthogonal one with respect to another. Of course, the first set and the
second set of
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spaced-apart lines may define another angle than a right angle. For example,
the angle
between the first set and the second set of spaced-apart lines may be included
in a closed
interval extending from 0 to 180. In some embodiments, each layer 20 may be
aligned
with a subsequent layer 20. In this configuration, the cushion pad 10 includes
a plurality
of aligned layers 20 and each layer 20 may be said to be in phase one with
respect to
another.
[0070] In other embodiments, each layer 20 may be misaligned with a subsequent
layer 20. In this configuration, the cushion pad 10 includes a plurality of
misaligned
layers 20 and each layer 20 may be said to be de-phased one with respect to
another. In
some embodiments, a spacing between two subsequent lines may be constant or
substantially constant over the layer 20. The two subsequent lines may be part
of the first
set and/or the second set of spaced-apart lines. In this configuration, the
period of the
layer 20 may be said to be constant and the layer 20 may be characterized as
being
"periodic". In other embodiments, a spacing between two subsequent lines may
be
different or substantially different over the layer 20. The two subsequent
lines may be part
of the first set and/or the second set of spaced-apart lines. In this
configuration, the period
of the layer 20 may be said to be non-constant and the layer 20 may be
characterized as
being "non-periodic". It should be noted that the properties of the cushion
pad 10 and the
layers 20, which may include, for example and without being !imitative,
alignment,
dephasing, change in thickness, and many others are selected and/or optimized
to modify
and/or improve the overall mechanical properties of the cushion pad 10, and
the item
incorporating such a cushion pad 10.
[0071] It should be understood that each cell 30 also has a thickness, and
that said
thickness can correspond to the thickness of the layer on which the cells 30
are defined.
It should thus be noted that a plurality of layers can be aligned with one
another to increase
the thickness of the cells 30. In such embodiments, the cells 30 of each layer
20 is aligned
with a corresponding cell 30 of a previous layer such that the cells 30 are
generally straight
and have a thickness substantially corresponding to a cumulative thickness of
the aligned
layers. It is noted that, if the layers are aligned throughout the cushion pad
10, the
thickness of the cells 30 substantially correspond to a thickness of the
cushion pad 10. In
alternate embodiments, the layers 20 can be created so as to be offset
relative to adjacent
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layers (i.e, layers above and/or below) throughout the cushion pad 10. The
layers can be
offset relative to one another by any suitable manner. For example, each
subsequent layer
can be axially offset following a direction of the segments from either sets
of segments
(e.g., along directions A or B as illustrated in Figure 3A). As such, it
should be understood
that the thickness of the cells increases and that the cells are at least
partially slanted
throughout a portion of the cushion pad. In other embodiments, it is
appreciated that the
layers can be axially offset relative to one another following any other
suitable direction,
such as any direction between directions A and B seen in Figure 3A.
[0072] Alternatively, or additionally, the layers can be rotationally offset
relative to a
previous and/or subsequent layer. For example, any given layer can be rotated
by any
suitable angle (e.g., 5, 10, 25, 30, 50, 100, 120, 150, 200 or 300 degrees,
etc.) relative to
a previously formed layer, thus creating a web of segments throughout the
cushion pad 10.
In some embodiments, it should be noted that rotating a layer includes
rotating the layer
in a plane substantially parallel to the plane in which is formed a previous
layer. As such,
although being offset (e.g., axially, rotationally, or a combination thereof),
each layer
remains substantially parallel to the other layers of the cushion pad 10.
[0073] As seen in Figures 27 to 30, in some embodiments, the layers can be
deposited
one on top of another according to a layering sequence. For example, a first
layer can be
formed with segments 22 extending in a first direction, and a second layer can
be
deposited/formed on top of the first layer with segments 24 extending in a
second direction
perpendicular from the first direction, and so on. In other words, each layer
is rotated by
about 90 degrees relative to the previous layer. This sequence can be referred
to as a 1:1
layering sequence (shown in Figure 27), where one (1) layer is formed in a
first direction
followed by one (1) layer in another direction. It is appreciated that the
layering sequence
can include any other suitable variations, such as a 2:2 layering sequence
(shown in
Figure 28), where two (2) layers are formed in a first direction followed by
two (2) layers
in another direction, or a 1:2 layering sequence (shown in Figure 29), a 2:1
layering
sequence, a 3:1 layering sequence (shown in Figure 30), a 1:3 layering
sequence, etc.
[0074] It should also be noted that the layering sequence can include layers
formed with
segments extending in additional directions, such as a third, a fourth
direction and/or any
suitable number of additional directions. In these embodiments, the layering
sequence can
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be a:b:c, where "a" corresponds to the number of layers with segments
extending in the
first direction (e.g., 1, 2, 3, etc.), "b" corresponds to the number of layers
with segments
extending in the second direction (e.g., 1, 2, 3, etc.), and "c" corresponds
to the number
of layers with segments extending in the third direction (e.g., 1, 2, 3,
etc.), and so on for
any suitable number of layers in a given direction and/or any suitable number
of directions.
In some embodiments, a single layer can include segments extending in more
than a
single direction. For example, a single layer can include a lattice pattern,
or a honeycomb
pattern, where segments extend in at least two different directions in the
same layer.
[0075] In some embodiments, the layers 20 can be substantially planar, e.g.,
formed in
respective planes, as illustrated in Figures 19 to 23. The segments of the
layers 20 can
be deposited on a substantially flat base 21 and built off of each other. As
such, each
plane, and therefore each layer 20, can be substantially parallel to other
planes (shown in
Figures 19 to 21). However, in other embodiments, each layer 20 can be angled
relative
to other layers 20 (Figures 22 and 23) such that the layers can include
respective 3D
orientations. In addition, it should be noted that at least some of the layers
20 can be non-
planar, as illustrated in Figures 24 to 26. The segments of the layers 20 can
be deposited
on a curved base 23 and subsequently built off of each other to create non-
planar layers
20. As such, and for example, bottom layers of cushion pads used in helmets
can be
planar, non-planar (e.g., curved) or multi-planar (e.g., formed of a plurality
of planar layers
angled relative to one another), such as to better conform to the shape of a
user's head
at different locations within the helmet. The cushion pads can therefore have
sections of
substantially planar layers combined with sections of non-planar layers and/or
multi-planar
layers. Alternatively, the entire pad can be made of multi-planar, non-planar
or planar
layers. It is appreciated that the non-planar layers can be different (e.g.,
different
curvatures) from one another within the same pad and/or from one pad to
another.
[0076] Now referring to Figure 4, the cushion pad 10, or at least a section
thereof, can
include cells 30 disposed so as to form a honeycomb pattern across the
corresponding
layer. In this embodiment, each layer can be positioned relative to adjacent
layers in any
suitable configuration, such as those previously described (e.g., axially
and/or rotationally
offset).
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[0077] In some embodiments, the cushion pad 10 is formed of a plurality of
cushion
sections 32, where each cushion section is formed of any suitable number of
layers having
any suitable configuration(s). For example, a first cushion section can be
formed of
relatively aligned layers forming generally straight cells 30. Another cushion
section can
be formed of axially offset layers, while yet another cushion section is
formed of rotationally
offset layers. It should also be noted that each cushion section 32, having
their respective
configurations of layers, can have respective resiliencies. In other words,
one cushion
section can be configured to greatly deform (e.g., for increased comfort)
while another
cushion section can be configured to only slightly deform (e.g., for increased
force
absorption). It should be noted that the layers can deform purely vertically,
purely
horizontally, at least partially vertically and/or horizontally, rotationally,
according to a
shear deformation or a combination thereof. It is also noted that a section of
the cushion
pad 10 having a repeating lattice pattern (seen in Figure 3) acts differently
under pressure
than a section having another configuration, such as a repeating honeycomb
pattern (seen
in Figure 4). For instance, a lattice pattern can provide additional control
on multidirectional
impact absorption behavior as compared to other patterns, such as solid foam,
for
example. In some embodiments, the cushion pad 10 can include one or more
sections
having a honeycomb patterns and one or more sections having a lattice pattern.
[0078] Referring back to Figures 1 and 2, in addition to Figure 5, the cushion
pad 10 can
include a pair of cushion sections 32, such as an outer cushion section 34 and
an inner
cushion section 36. In this embodiment, the outer cushion section 34 includes
a plurality
of generally aligned layers 20 having a honeycomb pattern, whereas the inner
cushion
section 36 includes a plurality of generally aligned layers 20 having a
lattice pattern. As
previously mentioned, the cushion pad 10 can be used to protect devices,
systems and/or
the person(s) using or operating such devices and/or systems. The inner and
outer
cushion sections 34, 36 can thus be configured provide shock absorption,
improve
protection and/or improve comfort. The cushion pad 10 can be used in
combination with
other similar cushion pads to form an array of cushion pads 10 adapted to
create a lining
for devices or systems, such as sporting equipment, for example.
[0079] In this embodiment, and with reference to Figures 1 and 2, each cushion
pad 10
can include an intermediate region 40 defined between the outer and inner
cushion
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sections 34, 36. As seen in Figures 1 and 2, the intermediate region 40 can
include tapered
portions of the outer and inner cushion sections 34, 36 defining a groove 42
around a
perimeter of the cushion pad 10. As will be described further below, the
cushion pad 10
can be installed in a support structure, where components of the support
structure are
adapted to engage the cushion pad along the groove 42. The cushion pad 10 can
therefore
be secured on the support structure (herein referred to as a "sling"), where
the wider
sections thereof on either side of the groove 42 at least partially prevent
removal of the
cushion pad 10 from the support structure.
[0080] With reference to Figures 6 to 9, in some embodiments, the cushion pad
10 is
part of an array of cushion pads forming a liner 45 for a helmet 50. In the
illustrated
embodiments, the helmet 50 corresponds to a football helmet, although it
should be noted
that other helmets and/or other types of equipment can include a liner 45
formed of a
plurality of cushion pads 10. The helmet 50 includes an outer shell 52 having
an outer
surface 54 and an inner surface 56, where the inner surface 56 defines a
cavity 55 of the
helmet 50 for receiving the head (H) of a person. The outer shell 52 also
defines a front
opening 57 enabling the person to see in front of him/her/them, with the
helmet 50 being
provided with a facemask 58 connected to the outer shell 52 for at least
partially protecting
the wearer's face (e.g., nose, mouth, eyes, etc.). It is appreciated that the
outer shell 52
further includes a bottom opening 59 enabling a person's head to engage the
cavity from
below. It should be noted that, in other embodiments, the helmet 50 can be
provided with
a visor (e.g., instead of, or in addition to the facemask) coupled to the
outer shell 52 and
being pivotable between open and closed positions for respectively opening and
closing
the front opening 57.
[0081] The cushion pads 10 are illustratively provided along the inner surface
56 of the
outer shell 52 such that the pads are positioned between the wearer's head and
the outer
shell 52 when wearing the helmet 50. It is appreciated that the cushion pads
10 can have
respective shapes, sizes, configurations or a combination thereof, based on
its position
along the inner surface 56, among others. Each cushion pad 10 can also be
installed
within the cavity 55 so as to position the outer cushion section 34 proximate
the outer shell
52 (e.g., connected to the inner surface 56) and position the inner cushion
section 36
within the cavity 55 to be positioned adjacent the head of a person wearing
the helmet 50.
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As seen in Figure 9, the inner cushion section 36 of each cushion pad 10 can
cooperate
to generally conform to a shape of a person's head.
[0082] As seen in Figures 10 to 12, in addition to Figures 6 to 9, the helmet
can include
a support structure 60 adapted to support the cushion pads 10 within the
cavity 55 along
the inner surface 56 of the helmet shell 52. The support structure 60 can be
shaped and
adapted to support each cushion pad 10 individually, i.e., independently from
the other
cushion pads 10. In this embodiment, the cushion pads 10 can be removably
installed on
the support structure 60, thereby enabling the removal of one or more cushion
pads 10 for
maintenance, replacement or repositioning, among others. As will be described
further
below, the support structure 60 can be removably coupled to the outer shell 52
and is
positioned so as to be spaced from a head of the person wearing the helmet 50
and
spaced from the inner surface 56.
[0083] In some embodiments, the support structure 60 can include a sling 62
connectable to the outer shell 52 and being shaped and sized to support the
cushion
pads 10. More specifically, the sling 62 can be made of a web of material 64
defining a
plurality of openings 65 for receiving the cushion pads 10. In this
embodiment, the sling 62
includes a generally continuous edge 63, and each one of the openings 65 is
complementarily shaped relative to one or more of the cushion pads 10 such
that the
cushion pad fits snugly within the corresponding opening 65. The sling 62 can
conform to
the shape of the outer shell 52, where the edge 63 is positioned along the
edges of the
front opening 57 and bottom opening 59. The sling 62 can include any suitable
number of
openings 65, such as two, four, ten, twenty or fifty openings, which can
correspond to the
number of cushion pads 10 installed within the helmet 50. In some embodiments,
the
sling 62 includes an axis of symmetry (S) where the openings 65 on a right
side of the
sling 62 are mirrored on a left side thereof. However, it is appreciated that
other
configurations are possible, such as having only a portion of the sling being
mirrored on
the right and left sides, or such as having no symmetry between the right and
left sides,
for example.
[0084] In some embodiments, the continuous edge 63 may be engineered to alter
the
general profile of the same. For example, the continuous edge 63 may include
variations
in thickness, shape and/or topology, and is generally designed to enhance or
generally
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17
improve the overall properties of the sling 62. Of note, the generally
continuous
structure 63 may have a different structure than the material forming the
sling 62.
[0085] Referring back to Figures 1 and 2, with continued reference to Figures
10 to 12,
in this embodiment, the web of material 64 is adapted to engage each cushion
pad 10
along the groove 42 defined along the intermediate region 40 thereof. The
cushion pad 10
can engage a corresponding one of the openings 65 until the inner cushion
section 36 is
provided on a first side of the sling 62, and the outer cushion section 34 is
provided on a
second opposite side of the sling 62. The resiliency of the cushion pad 10 can
enable
deformation thereof for insertion within the opening 65. Once in the desired
position, where
the web of material 64 is provided along the groove 42, the cushion pad 10 is
released
and reverts to an initial shape and size. The outer and inner cushion sections
34, 36 can
at least partially extend over the sling 62 (e.g., over the web of material
surrounding the
cushion pad) such that the cushion pad is at least partially secured within
the opening 65.
Each cushion pad 10 is installed in the sling 62 in a similar manner so as to
form a
protective lining which can be installed within protective gear, such as along
the inner
surface of the helmet 50.
[0086] With reference to Figures 10 to 12, the sling 62 can include support
members 66
adapted to be connected to the outer shell 52, such as to the inner surface
thereof. In
some embodiments, the support members 66 can be fastened to the inner surface
using
any suitable method, such as mechanical fasteners, adhesive, interference fit,
among
other possibilities. The support members 66 can be adapted to position the web
of material
64 in a spaced-apart relation relative to the inner surface 56 of the outer
shell 52. It is
appreciated that the cushion pads 10 can thus be positioned within the cavity,
with the
outer cushion section 34 extending between the outer shell 52 and the sling
62, and the
inner cushion section 36 extending within the cavity, such as between the
sling 62 and the
head of the person wearing the helmet 50. In this embodiment, the support
members 66
include spacers 68 extending outwardly from the web of material 64 at various
locations
around the sling 62, and connection pads 70 provided at a distal end of the
spacers 68.
The connection pads 70 are connectable to the outer shell 52, with the spacers
68
positioning the web of material 64 in the spaced-apart position relative to
the outer shell
52, as previously described.
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[0087] In this embodiment, the components of the sling 62 (e.g., the web of
material 64
and/or the support members 66) can be made of resilient material adapted to
enable
relative movement between the components of the sling, between the sling and
the outer
shell 52 and/or between the sling and the cushion pads. For example, the
application of a
force on the outer shell 52 can push the support members 66 inwardly (e.g.,
towards the
web of material 64) enabling compression of the outer cushion section 34 to
absorb at
least a portion of the applied force. It is noted that the inner cushion
section 36, along with
the web of material 64, can simultaneously deform to further absorb some of
the applied
force.
[0088] In some embodiments, the sling is made from a plastic material or
rubber. It is
noted that the sling can be manufactured via a similar process to the cushion
pads (e.g.,
additive manufacturing).
[0089] In the illustrated embodiments, the sling 62 is positioned
substantially in the
middle of the cushion pads 10, with the inner and outer cushion sections being
relatively
the same size as one another. However, it is appreciated that other
configurations are
possible. As seen in Figures 13 to 15, the cushion pads 10 can be provided
with grooves
provided proximate a bottom end and/or a top end thereof, so as to position
the sling
accordingly, e.g., proximate the bottom end (Figure 13) or proximate the top
end
(Figure 15). In alternate embodiments, the helmet (or protective garment) can
be provided
with two or more slings 62, where each sling is adapted to hold respective
sets of cushion
pads 10 within the helmet, and where each sling can be provided at respective
heights
along the cushion pads 10 they are holding. Other embodiments are possible, as
will be
understood by a person of ordinary skill in the art.
[0090] Now turning to Figures 16 to 18, there is illustrated an embodiment of
the
configuration or distribution of the cushion pads 10 within a helmet
structure. It should be
noted that the material density may vary from one cushion pad 10 to another,
or between
different regions of the helmet structure. More specifically, different types
of cushion
pads 10 may be provided at different locations of the helmet structure. Two
cushion
pads 10 of different types will generally have a least one different property,
which may
include, for example, density, stiffness, behavior, geometry, and the weight.
In some
embodiments, cushion pads 10 having a predetermined weight may be provided at
given
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locations of the helmet structure, depending on the mechanical requirements of
the
respective helmet portions. The size of the individual cells forming the
cushion pad 10 may
also vary. For example, each cell may have a dimension substantially equal to
3 mm,
4 mm, 5 mm or 6 mm. It should be readily understood that these values serve an
illustrative purpose only.
[0091] It should be appreciated from the present disclosure that the various
implementations of the helmet, and corresponding components, provide several
advantages over conventional devices and/or apparatus in that it provides
additional
protection against collisions, such as those suffered by the helmets of
football players, for
example.
[0092] The present disclosure may be embodied in other specific forms without
departing
from the subject matter of the claims. The described example implementations
are to be
considered in all respects as being only illustrative and not restrictive. For
example, in the
embodiments described herein, the cushion pads are used to provide a liner
within a
football helmet. However, it is noted that other types of gear or equipment
can be provided
with such cushion pads, such as, for example and without being !imitative,
plastron, chest
pad, shoulder pad, knee pad, elbow pad, back protector pad, neck protector
pad, neck
roll, pad collar and neck guard.
[0093] In some embodiments, the connection pads 70 allows a relative movement
of the
sling 62 with respect to the other components of the helmet, i.e.,
independently of the
movement of the outer shell 52 or the head of the user. The mechanical
properties of the
connection pads 68,70 are designed or selected to achieve a targeted mobility,
and allow
a relative movement of the sling 62.
[0094] The present disclosure intends to cover and embrace all suitable
changes in
technology. The scope of the present disclosure is, therefore, described by
the appended
claims rather than by the foregoing description. The scope of the claims
should not be
limited by the implementations set forth in the examples, but should be given
the broadest
interpretation consistent with the description as a whole.
[0095] As used herein, the terms "coupled", "coupling", "attached",
"connected", or
variants thereof as used herein can have several different meanings depending
in the
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context in which these terms are used. For example, the terms coupled,
coupling,
connected, or attached can have a mechanical connotation. For example, as used
herein,
the terms coupled, coupling, or attached can indicate that two elements or
devices are
directly connected to one another or connected to one another through one or
more
intermediate elements or devices via a mechanical element depending on the
particular
context.
[0096] In the present disclosure, an embodiment is an example or
implementation of the
perforation blade. The various appearances of "one embodiment," "an
embodiment" or
"some embodiments" do not necessarily all refer to the same embodiments.
Although
various features may be described in the context of a single embodiment, the
features
may also be provided separately or in any suitable combination. Conversely,
although the
helmet and related components may be described herein in the context of
separate
embodiments for clarity, it may also be implemented in a single embodiment.
Reference
in the specification to "some embodiments", "an embodiment", "one embodiment",
or
"other embodiments", means that a particular feature, structure, or
characteristic
described in connection with the embodiments is included in at least some
embodiments,
but not necessarily in all embodiments.
[0097] In the above description, the same numerical references refer to
similar elements.
Furthermore, for the sake of simplicity and clarity, namely so as to not
unduly burden the
figures with several references numbers, not all figures contain references to
all the
components and features, and references to some components and features may be
found in only one figure, and components and features of the present
disclosure which
are illustrated in other figures can be easily inferred therefrom.
[0098] In addition, although the optional configurations as illustrated in the
accompanying
drawings comprises various components and although the optional configurations
of the
helmet and related components as shown may consist of certain geometrical
configurations as explained and illustrated herein, not all of these
components and
geometries are essential and thus should not be taken in their restrictive
sense, i.e. should
not be taken as to limit the scope of the present disclosure. It is to be
understood that
other suitable components and cooperations thereinbetween, as well as other
suitable
geometrical configurations may be used for the implementation and use of the
robot cell,
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and corresponding parts, as briefly explained and as can be easily inferred
herefrom,
without departing from the scope of the disclosure.
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