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WO2015116750A1 - Casques de protection - Google Patents

Casques de protection Download PDF

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Publication number
WO2015116750A1
WO2015116750A1 PCT/US2015/013407 US2015013407W WO2015116750A1 WO 2015116750 A1 WO2015116750 A1 WO 2015116750A1 US 2015013407 W US2015013407 W US 2015013407W WO 2015116750 A1 WO2015116750 A1 WO 2015116750A1
Authority
WO
WIPO (PCT)
Prior art keywords
cushioning
shell
foam
layer
hard
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2015/013407
Other languages
English (en)
Inventor
Yochanan COHEN
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US14/171,283 external-priority patent/US9578917B2/en
Application filed by Individual filed Critical Individual
Publication of WO2015116750A1 publication Critical patent/WO2015116750A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • A—HUMAN NECESSITIES
    • A42—HEADWEAR
    • A42B—HATS; HEAD COVERINGS
    • A42B3/00—Helmets; Helmet covers ; Other protective head coverings
    • A42B3/04—Parts, details or accessories of helmets
    • A42B3/10—Linings
    • A42B3/12—Cushioning devices
    • A42B3/125—Cushioning devices with a padded structure, e.g. foam
    • A—HUMAN NECESSITIES
    • A42—HEADWEAR
    • A42B—HATS; HEAD COVERINGS
    • A42B3/00—Helmets; Helmet covers ; Other protective head coverings
    • A42B3/04—Parts, details or accessories of helmets
    • A42B3/06—Impact-absorbing shells, e.g. of crash helmets
    • A42B3/062—Impact-absorbing shells, e.g. of crash helmets with reinforcing means
    • A42B3/063—Impact-absorbing shells, e.g. of crash helmets with reinforcing means using layered structures
    • A—HUMAN NECESSITIES
    • A42—HEADWEAR
    • A42B—HATS; HEAD COVERINGS
    • A42B3/00—Helmets; Helmet covers ; Other protective head coverings
    • A42B3/04—Parts, details or accessories of helmets
    • A42B3/06—Impact-absorbing shells, e.g. of crash helmets
    • A42B3/069—Impact-absorbing shells, e.g. of crash helmets with soft external layer, e.g. for use in impact sports
    • A—HUMAN NECESSITIES
    • A42—HEADWEAR
    • A42B—HATS; HEAD COVERINGS
    • A42B3/00—Helmets; Helmet covers ; Other protective head coverings
    • A42B3/04—Parts, details or accessories of helmets
    • A42B3/10—Linings
    • A42B3/12—Cushioning devices
    • A42B3/124—Cushioning devices with at least one corrugated or ribbed layer

Definitions

  • the present disclosure relates to helmets. More particularly, the present disclosure relates to protective helmets having enhanced protective performance characteristics.
  • the present disclosure has application to football helmets, ice-hockey helmets, baseball helmets, motorcycle helmets, riot helmets, military helmets and other similar helmets, although it is not limited thereto.
  • Head trauma resulting from sports and other activities is a common occurrence.
  • head trauma occurs when an object impacts the head, thereby transferring energy to the head.
  • the most common head trauma resulting from sports is a concussion, which occurs when the brain bangs inside the skull and is bruised.
  • concussion To reduce the incidence of concussion, it is common practice to wear a protective helmet.
  • Protective helmets are ostensibly designed to deflect and absorb energy transmitted by impact to the helmet, thereby diminishing the risk of head and brain injury resulting from the impact.
  • TBI head trauma resulting in traumatic brain injury
  • TBI injuries fall into several categories that may have different symptoms.
  • Mild TBI commonly referred to as a concussion, is a brief loss of consciousness or disorientation ranging up to thirty minutes.
  • brain damage may not be visible on an MRI or CAT scan, common symptoms of MTBI include headache, confusion, lightheadedness, dizziness, blurred vision, ringing in the ears, fatigue or lethargy, behavioral or mood changes, and trouble with memory, concentration or attention.
  • Severe traumatic brain injury is associated with loss of consciousness for over thirty minutes or amnesia.
  • TBI Symptoms of severe TBI include all those of MTBI as well as headaches that increase in severity or do not abate, repeated vomiting or nausea, convulsions or seizures, dilation of the eye pupils, slurred speech, weakness or numbness in the extremities, loss of coordination, and increased confusion or agitation. TBI injuries can cause lasting physical and cognitive damage.
  • the U.S. army utilizes the Advanced Combat Helmet (ACH) that incorporates ballistic fiber such as KEVLAR (a trademark of DuPont of Wilmington, DE), TWARON (a trademark of Teijin Twaron, B.V. of the Netherlands), or ultra-high-molecular- weight polyethylene (UHMWPE) .
  • the ACH has a suspension system including a rear suspension system to which a ballistic "nape pad" is attached. The nape pad is intended to reduce solider deaths from shrapnel wounds to the neck and lower head.
  • a protective helmet includes a multilayered system including at least two outer cushioning layers having different densities and different geometric layouts, a hard structure located inside the outer cushioning layers, and at least one inner cushioning layer located inside the hard structure.
  • the outer layer of the at least two outer cushioning layers is a cushioning outer shell
  • an inner layer of the at least two outer cushioning layers is a spacer layer with a different geometry than the cushioning outer shell and which is arranged to redirect energy transmitted from the cushioning outer shell along a circuitous path to air and the hard inner structure.
  • the hard structure located inside the outer cushioning layers is a multilayer structure with at least two hard layers and at least one cushioning layer
  • the at least two hard layers may composite carbon fiber structures
  • the cushioning layer may be structural foam or a liquid gel.
  • the at least one inner cushioning layer located inside the hard inner structure includes at least two cushioning layers having different densities and different geometric layouts. In one embodiment, the at least two cushioning layers located inside the inner structure are similar in densities and geometry to the at least two outer cushioning layers. In another embodiment, the at least one inner cushioning layer located inside the hard inner structure is a plurality of innermost cushioning pads coupled to the inside of the hard inner structure.
  • one or more of the inner cushioning layers located inside the hard inner structure is provided with a plurality of spaced impact sensors.
  • an innermost cushioning layer incorporates a thermal or climate control system that can be used to absorb, store and release heat for thermal comfort.
  • the cushioning outer shell is covered by a fiexible thin cover.
  • the flexible thin cover may be a fabric, film, foil, or other cover.
  • the flexible thin cover may be cosmetic and may provide a surface for printing graphics.
  • the flexible thin cover may also protect the cushioning outer shell from damage.
  • the cushioning spacer layer includes a plurality of elements glued or otherwise attached to the cushioning outer shell and to the hard inner structure.
  • the cushioning spacer layer comprises a single member defining a plurality of spaces.
  • the cushioning spacer layer member or elements at least partially overlie the spaces defined by the hard inner structure.
  • one or more of cushioning layers or elements is formed from a foam material such as an elastomeric, cellular foam material.
  • one or more of the cushioning layers is made of thermoplastic polyurethane (TPU).
  • one or more of the cushioning layers is made from a microcellular urethane foam.
  • a military helmet includes a multilayered system including at least two outer cushioning layers having different densities and different geometric layouts, a hard ballistic resistant structure located inside the outer cushioning layers, and at least one inner cushioning layer located inside the hard structure.
  • the outer layer of the at least two outer cushioning layers is a cushioning outer shell
  • an inner layer of the at least two outer cushioning layers is a spacer layer with a different geometry than the cushioning outer shell and which is arranged to redirect energy transmitted from the cushioning outer shell along a circuitous path to air and the hard ballistic resistant structure.
  • the at least two outer cushioning layers of the military helmet serve the purpose of absorbing or deflecting an acoustic shock wave that can impact the military helmet in advance of the impact of a projectile (e.g., bullet).
  • a projectile e.g., bullet
  • the hard ballistic resistant structure located inside the outer cushioning layers is a multilayer structure with at least two ballistic fiber composite layers and at least one cushioning layer therebetween.
  • the at least two ballistic fiber composite layers may be a material such as KEVLAR
  • the cushioning layer may be structural foam or a liquid gel.
  • the cushioning outer shell of the military helmet is covered by a flexible thin cover.
  • the flexible thin cover may be a fabric, film, foil, or other cover such as a ballistic nylon (a high denier nylon thread with a dense basket weave) that is used as a cover for the ACH.
  • the flexible thin cover may provide a surface for printing graphics (e.g.,
  • the flexible thin cover may also protect the cushioning outer shell from damage.
  • one or more of the inner cushioning layers of the military helmet located inside the hard ballistic resistant inner structure is provided with a plurality of spaced impact sensors.
  • an innermost cushioning layer of the military helmet incorporates a thermal or climate control system that can be used to absorb, store and release heat for thermal comfort.
  • FIG. 1 is a perspective exploded view of a first embodiment of a helmet.
  • Fig. 2 is a front perspective view of the first embodiment.
  • Fig. 3 is an inside perspective view of the first embodiment.
  • Fig. 4 is a side view of the first embodiment.
  • Fig. 5 is a cross-sectional view of the first embodiment.
  • Fig. 6a is a perspective view of an alternative cushioning spacer layer.
  • Fig. 6b is a perspective view of an alternative hard inner structure.
  • FIGs. 7a and 7b are bottom and perspective views of an embodiment of a football helmet.
  • Fig. 8 is a perspective exploded view of an embodiment of a military helmet.
  • Fig. 9 is a side view of the military helmet embodiment.
  • Fig. 10 is a cross-sectional view of military helmet embodiment. [0038] Fig.
  • FFiigg.. 12 is a perspective view of a military helmet including straps and accessories.
  • FFiigg.. 13 is a perspective exploded view of an embodiment of a riot helmet.
  • FFiigg.. 15 is a view of an alternate cushioning spacer layer for the riot helmet.
  • FFiigg.. 16 is a cross-sectional view of the riot helmet of Fig. 13.
  • FFiigg.. 17 is a perspective exploded view of an embodiment of a helmet utilizing the alternate cushioning spacer layer of Fig. 15.
  • Fig. 18 is a perspective exploded view of layers of an embodiment of a helmet.
  • Figs. 19a- 19c are respectively a perspective exploded view of the outer layers of a portion of a football helmet, a perspective view of a hard multilayer of a portion of a football helmet, and a perspective exploded view of the inner layers of a portion of a football helmet.
  • Fig. 20 is an exploded view of another embodiment of the inner layers of a helmet.
  • Helmet 10 includes a multilayered system including an optional outermost cover 15, a cushioning outer shell 20 having an outer surface 22 and an inner surface 24, a hard inner structure 40 with an outer surface 42 and an inner surface 44, a cushioning spacer layer 30 located between and separating the cushioning outer shell 20 and the hard inner structure 40, and one or more innermost cushioning pads 50 coupled to the inside surface 44 of the hard inner structure 40.
  • the innermost cushioning pads 50 may be covered by another fabric layer 55.
  • the cushioning spacer layer 30 separates the cushioning outer shell 20 from the hard inner structure 40 and redirects energy transmitted from the cushioning outer shell along a circuitous path to air gaps and to the hard inner structure, thereby causing dissipation of pressure wave energy. Pressure wave energy that does reach the hard inner structure 40 is further dissipated by the innermost cushioning pads 50 before reaching the head of the helmet user (not shown).
  • the material of the hard inner structure 40 is considerably harder than the material(s) of the cushioning outer shell layer 20 and the cushioning spacer layer 30.
  • the material(s) of the cushioning outer shell layer 20 and the cushioning spacer layer are resilient.
  • the cushioning spacer layer defines gaps that are nonuniform in shape and/or in size.
  • the cushioning outer shell 20 will absorb and/or distribute some or all of the energy.
  • the energy may be absorbed by (resilient) deflection of the foam cushioning. If some of the energy passes through the cushioning outer shell 20 it can either pass into the cushioning spacers 30 or into the air between the cushioning spacers. Again, if the energy pass into the cushioning spacers, the energy may be absorbed by (resilient) deflection of the cushioning spacers.
  • the energy may be absorbed in the air between the cushioning spacers.
  • Energy passing through the cushioning spacer level will reach the hard inner structure 40 or air gaps therein where it can be one or more of reflected, distributed, absorbed or transmitted.
  • the hard inner structure 40 will not absorb much energy.
  • the function of the hard inner structure 40 is primarily one of lending structural integrity to the helmet 10. Any energy passing through the hard inner structure or the air gaps therein will be passed to the innermost cushioning pads 50 (also typically resilient) or the air gaps between the pads where the energy again may be absorbed by (resilient) deflection of the cushioning pads 50 or by the air gaps therein.
  • a first cross section at location A through the helmet shows a fabric cover 15, the cushioning shell 20, a cushioning spacer pad 30, a hard inner structure 40, an inner cushioning pad 50, and an inner fabric cover 55 for the inner cushioning pad 50.
  • Location B shows the cover 15, cushioning shell 20, space 35 (e.g., air between the cushioning spacer pads 30), the hard inner structure 40, an inner cushioning pad 50, and an inner fabric cover 55 for the inner cushioning pad 50.
  • Location C includes cover 15, the cushioning shell 20, a cushioning pad 30, space 45 (e.g., air at gaps in the hard shell 40), and additional space 55 (e.g., air at gaps between the inner cushioning pads 50).
  • Location D shows the cover 15, the cushioning shell 20, space 35 (e.g., air between the cushioning spacer pads 30), additional space (e.g., air at gaps in the hard shell 40), an inner cushioning pad 50, and fabric cover 55.
  • Location E includes the cover 15, the cushioning shell 20, the cushioning spacer pad 30, the hard inner structure 40, and space 55 (e.g., air gap between the inner cushioning pads 50).
  • Location F shows the cover 15, the cushioning shell 20, space 35 between the cushioning spacer pads 30, space 45 (air gaps in the hard shell), an inner cushioning pad 50 and fabric cover 55.
  • the described cross-sections give certain energy paths through the helmet 10, but that many other exist, and it is not necessary that all of these paths exist simultaneously in a helmet.
  • energy waves will generally take a path of least resistance through a substance which may not correspond exactly to any of the cross-sections. Because harder substances will generally transmit energy waves more readily than air, the air gaps will cause the energy to travel and spread radially through the cushioning shell 20 and the hard inner structure 40. However, travel through a longer distance in the cushioning shell 20 and the hard inner structure 40 causes further attenuation of the energy.
  • the flexible thin cover 15 may be a fabric, film, foil, leather, or other cover.
  • the flexible thin cover may be cosmetic and may provide a surface for printing graphics.
  • the flexible thin cover may also protect the cushioning outer shell from damage.
  • the flexible thin cover may extend around the periphery of the helmet (as suggested in Fig. 5 but not shown in Figs. 2 and 3) to protect the periphery of the cushioning shell 20 and the cushioning spacer layer 30 and optionally the hard inner structure 40 and even the innermost cushioning pads 50.
  • a flexible band may be used to extend around the periphery and cover the peripheral edge of cushioning shell 20, the spacer layer 30 and optionally the hard layer 40.
  • the flexible thin cover is made from ballistic nylon, a high denier nylon thread with a dense basket wave such as Cordura (a trademark of Invista, Wichita, Kansas).
  • the flexible thin cover is made from a Neoprene (a trademark of DuPont, Delaware) rubber (polychloroprene) fabric.
  • the flexible thin cover is made from leather or artificial leather.
  • the flexible thin cover is made from a polyester fabric.
  • the flexible thin cover is made from non- woven fabric.
  • the flexible thin cover is made from a printable film.
  • the thin cover may be between 0.1mm and 10mm thick, although it may be thinner or thicker.
  • the flexible thin cover may be between 0.3mm and 3.25mm thick.
  • the flexible thin cover may be between 1.0mm and 1.5mm thick.
  • the thin cover 15 may be attached at one or more places to the cushioning shell 20, so that the cover may be removed from the shell 20 without damaging the shell.
  • attachment may be made by use of Velcro (a trademark of Velcro USA Inc., Manchester, New Hampshire).
  • the thin cover may be glued, tacked or sewn to the shell 20.
  • the thin cover 15 covers the entire cushioning shell 20.
  • the cushioning shell 20 is comprised of foam.
  • the foam may be an elastomeric, cellular (including microcellular) foam or any other desirable foam.
  • the cushioning shell is comprised of a soft resilient thermoplastic polyurethane (TPU) (i.e., having a Shore hardness considerably below the Shore hardness of the hard inner structure).
  • TPU thermoplastic polyurethane
  • the cushioning shell is comprised of open-cell
  • the cushioning shell is comprised of closed cell polyolefin foam.
  • the cushioning shell is comprised of polyethylene foam which may be a high or low density polyethylene foam.
  • the outer surface 22 of the cushioning shell 20 is generally (hemi)-spherical in shape.
  • the cushioning shell may be between 3mm and 13mm thick, although it may be thinner or thicker.
  • the cushioning shell may have a density of between 3.4 lbs/ft 3 (approximately 0.016 g/cm 3 ) and 25 lbs/ ft 3 (approximately 0.4 g/cm 3 ), although it may be more dense or less dense.
  • the cushioning spacer layer 30 comprises a plurality of pads 31.
  • the pads 31 may be circular in shape or may be formed in other shapes. Multiple shapes may be used together.
  • the spacer layer may include a strip of material 33 (seen in Fig. 1) around the peripheral edge of the helmet between the shell 20 and the hard inner structure 40 that can prevent foreign material from entering between the shell 20 and the hard inner structure 40.
  • the cushioning spacer layer is a single pad 30a defining multiple cut-outs 35a (i.e., the equivalent of multiple connected pads).
  • the spacer layer 30 is comprised of foam.
  • the foam may be an elastomeric, cellular (including microcellular) foam or any other desirable foam.
  • the cushioning spacer layer is comprised of a soft resilient thermoplastic polyurethane (TPU) that is considerably softer than the hard inner structure 40.
  • the cushioning spacer layer is comprised of open-cell polyurethane.
  • the cushioning spacer layer is comprised of closed cell polyolefin foam.
  • the cushioning spacer layer is comprised of a microcellular urethane foam such as PORON (a trademark of Rogers Corporation).
  • the cushioning spacer layer is comprised of polyethylene foam which may be a high or low density polyethylene foam.
  • the cushioning spacer layer 30 has multiple layers formed from different materials.
  • the cushioning spacer layer may be between 3mm and 26mm thick, although it may be thinner or thicker.
  • the cushioning spacer layer may be between 6 and 13mm thick.
  • the cushioning spacer layer may have a density of between 3.4 lbs/ft 3 (approximately 0.016 g/cm 3 ) and 30 lbs/ ft 3 (approximately 0.48 g/cm 3 ), although it may be more dense or less dense.
  • the spacer layer 30 covers approximately fifty percent of the inner surface area of the shell 20. In another embodiment, the spacer layer 30 covers between twenty percent and ninety-five percent of the inner surface area of the shell. The spacer layer 30 should cover sufficient area between the shell 20 and the hard inner structure 40 so that upon most expected impacts to the helmet 10, the shell 20 does not directly come into contact with the hard inner structure 40. Regardless of the material and arrangement of the cushioning spacer layer 30, in one embodiment the cushioning material is affixed to the shell 20 and to the hard inner structure. Affixation can be done with glue, Velcro or any other affixation means. [0057] In one embodiment, the hard inner structure 40 is comprised of a polycarbonate shell.
  • the hard inner structure 40 is comprised of a different hard plastic such a polypropylene. In another embodiment, the hard inner structure 40 is comprised of ABS resin. In another embodiment, the hard inner structure 40 is made of carbon fiber or fiberglass. In another embodiment, the hard inner structure is made of a polypropylene which is considerably harder than the materials of the cushioning layer 20 and spacer layer 30.
  • the hardness of the hard inner structure may be characterized by a hardness on the Shore D Durometer scale (typically Shore D 75 and over), whereas generally, the hardness of the materials of the cushioning layer 20 and the spacer layer 30 are characterized by a hardness on the Shore A Durometer scale (typically Shore A 60 and under, and even more typically Shore A 30 and under).
  • the hard inner structure 40 defines a plurality of cut-outs 45. In one embodiment at least one of the cut-outs 45 is at least partially covered by a cushioning spacer pad 30. In another embodiment, at least one of the cut-outs 45 is at least partially covered by an inner cushioning pad 50.
  • the hard inner structure 40 is affixed to the spacer layer 30. Affixation can be done with glue, Velcro or any other affixation means.
  • the hard inner structure is between 1.5mm and 6.0mm thick, although it may be thinner or thicker.
  • the hard inner structure 40 is between 2.5mm and 3.1mm thick.
  • the one or more innermost cushioning pad(s) 50 is comprised of foam.
  • the foam may be an elastomeric, cellular (including microcellular) foam or any other desirable foam.
  • the cushioning pad(s) 50 is comprised of a soft resilient thermoplastic polyurethane (TPU).
  • the cushioning pad(s) is comprised of open-cell polyurethane.
  • the cushioning pad(s) is comprised of closed cell polyolefm foam.
  • the cushioning pad(s) is comprised of polyethylene foam which may be a high or low density polyethylene foam.
  • the innermost cushioning pad 50 is a single pad defining multiple cut-outs (i.e., the equivalent of multiple connected pads). In another embodiment, a plurality of innermost cushioning pads 50 are provided. Regardless, the single pad with the cut-outs or the multiple pads are arranged in a desired configuration and are affixed to the hard inner structure 40. Affixation can be done with glue, Velcro or any other affixation means.
  • the innermost cushioning layer may be between 3mm and 26mm thick, although it may be thinner or thicker.
  • the innermost cushioning pads may have a density of between 3.4 lbs/ft 3 (approximately 0.016 g/cm 3 ) and 25 lbs/ ft 3 (approximately 0.4 g/cm 3 ), although they may be more dense or less dense.
  • the innermost cushioning pad(s) 50 is covered by a fabric layer 55 (seen in Fig. 5).
  • fabric layer 55 is absorbent.
  • fabric layer 55 is removable from the foam pad(s) 50.
  • the flexible thin cover is made from ballistic nylon, a high denier nylon thread with a dense basket wave such as Cordura (a trademark of Invista, Wichita, Kansas).
  • the flexible thin cover is made from a Neoprene (a trademark of DuPont, Delaware) rubber (polychloroprene) fabric.
  • the flexible thin cover is made from leather or an artificial leather.
  • the flexible thin cover is made from a polyester fabric.
  • the flexible thin cover is made from non-woven fabric.
  • the thin cover may be between 0.3mm and 3.25mm thick, although it may be thinner or thicker.
  • the flexible thin cover may be between 1.0mm and 1.5mm thick.
  • Hard inner structure 40a includes a plurality of horizontal frame members 47a and lateral frame members 49a that together define spaces 45 a.
  • hard inner structure 40a effectively defines a lattice for support of the remainder of the helmet.
  • the spaces 45a are roughly equal in area to one-half the area taken by the frame members 47a and 49a.
  • the spaces 45 a are roughly equal to between one-quarter and twice the area taken by the frame members 47a and 49a.
  • a riot helmet can have a polycarbonate face extending from the front face of the helmet.
  • a football helmet 110 is provided with the layered structure described above with reference to Figs.
  • the face guard 190 is of the type that can break away from the remainder of the helmet 110 when subjected to excessive twisting forces.
  • the football helmet 110 has a thickness of between 20mm and 50mm, although it may be thinner or thicker.
  • Helmet 210 includes a multilayered system including an optional outermost cover 215, a cushioning outer shell 220 having a convex outer surface 222 and a concave inner surface 224, a hard ballistic- resistant inner shell 240 with a convex outer surface 242 and a concave inner surface 244, a cushioning spacer layer 230 located between and separating the cushioning outer shell 220 and the hard inner shell 240, and one or more innermost cushioning pads 250 coupled to the inside surface 244 of the hard inner shell 240.
  • the innermost cushioning pads 250 may be covered by another fabric layer 260.
  • the cushioning spacer layer 230 separates the cushioning outer shell 220 from the ballistic-resistant inner shell 240 and redirects energy transmitted from the cushioning outer shell along a circuitous path to air gaps and to the ballistic-resistant inner shell, thereby causing dissipation of shock (pressure) wave energy.
  • Pressure wave energy that does reach the ballistic-resistant inner shell 240 is further dissipated by the innermost cushioning pads 250 before reaching the head of the helmet user (not shown).
  • an energy wave hits the helmet.
  • This energy wave can be a significant percentage of the total energy (energy or shock wave energy plus projectile energy) that impacts the helmet. In fact, in some circumstances, it is possible that only a shock wave is received, in which case, the shock wave is 100% of the total energy impacting the helmet.
  • the military helmet 210 is designed to lessen the total energy impact on its user in two separate manners. First, the energy wave can take various paths. For example, it should be appreciated that the cushioning outer shell 220 will absorb and/or distribute some or all of the energy. The energy may be absorbed by deflection of the foam cushioning.
  • the energy passes through the cushioning outer shell 220 it can either pass into the cushioning spacers 230 or into the air between the cushioning spacers. Again, if the energy passes into the cushioning spacers, the energy may be absorbed by deflection of the cushioning spacers. Alternatively or in addition, the energy may be absorbed in the air between the cushioning spacers. Energy passing through the cushioning spacer level will reach the hard inner shell where it can be one or more of reflected, distributed, absorbed or transmitted. Energy passing through the hard inner ballistic-resistant will be passed to the innermost cushioning pads 250 or the air gaps between the pads where the energy again may be absorbed by deflection of the cushioning pads 250 or by the air gaps therein.
  • the energy imparted by the energy shock wave will be significantly dissipated before reaching the head of the user.
  • the resistance to the energy shock waves by the helmet is increased. In this manner, the incidence of brain concussions of wearers of the military helmet 210 can be reduced.
  • the military helmet 210 is also adapted to lessen the impact of the projectile itself.
  • the cushioning outer shell 220 and the cushioning spacer layer 230 will not appreciably stop the projectile
  • the hard inner shell 240 formed from a ballistic-resistant material will act to stop the projectile in the manner of the previously described with reference to the Advanced Combat Helmet.
  • FIG. 10 shows three different cross-sectional paths through the military helmet.
  • a first cross section at location A through the military helmet shows a fabric cover 215, the cushioning shell 220, a cushioning spacer pad 230, a ballistic-resistant inner shell 240, an inner cushioning pad 250, and an inner fabric cover 260 for the inner cushioning pad 250.
  • Location B shows the cover 215, cushioning shell 220, space 235 (e.g., air between the cushioning spacer pads 230), the ballistic-resistant inner shell 240, an inner cushioning pad 250, and an inner fabric cover 260 for the inner cushioning pad 250.
  • Location C includes the cover 215, the cushioning shell 220, the cushioning spacer pad2 30, the ballistic-resistant inner shell 240, and space 255 (e.g., air gap between the inner cushioning pads 50).
  • the described cross-sections give certain energy paths through the military helmet 210, but that many other exist, and it is not necessary that all of these paths exist simultaneously in a military helmet.
  • energy waves will generally take a path of least resistance through a substance that may not correspond exactly to any of the cross-sections. Because harder substances will generally transmit energy waves more readily than air, the air gaps will cause the energy to travel and spread radially through the cushioning shell 220 and the hard inner shell 240. However, travel through a longer distance in the cushioning shell 220 and the ballistic-resistant inner shell 240 causes further attenuation of the energy.
  • the flexible thin cover 215 may be a fabric, film, foil, or other cover such as a ballistic nylon (a high denier nylon thread with a dense basket weave) that is used as a cover for the ACH.
  • the flexible thin cover may provide a surface for printing graphics, e.g., camouflage (see Fig. 12).
  • the flexible thin cover may also protect the cushioning outer shell from damage.
  • the flexible thin cover may extend around the periphery of the helmet (as suggested in Fig. 10) to protect the periphery of the cushioning shell 220 and the cushioning spacer layer 230 and optionally the hard inner shell 240 and even the innermost cushioning pads 250.
  • a flexible band may be used to extend around the periphery and cover the peripheral edge of cushioning shell 220, the spacer layer 230 and optionally the hard shell 240.
  • the flexible thin cover is made from ballistic nylon, a high denier nylon thread with a dense basket weave such as Cordura (a trademark of Invista, Wichita, Kansas).
  • the flexible thin cover is made from a Neoprene (a trademark of DuPont, Delaware) rubber (polychloroprene) fabric.
  • the flexible thin cover is made from a polyester fabric.
  • the flexible thin cover is made from leather or artificial leather.
  • the flexible thin cover is made from non-woven fabric.
  • the flexible thin cover is made from a printable film.
  • the flexible thin cover is made from a para-aramid synthetic fiber such as KEVLAR (a trademark of DuPont of Wilmington, DE).
  • the flexible thin cover comprises TWARON (a trademark of Teijin Twaron, B.V. of the Netherlands).
  • the flexible thin cover is made from a ultra-high-molecular-weight polyethylene.
  • the thin cover may be between 0.1mm and 10mm thick, although it may be thinner or thicker.
  • the flexible thin cover may be between 0.3mm and 3.25mm thick.
  • the flexible thin cover may be between 1.0mm and 1.5mm thick.
  • the thin cover 215 may be attached at one or more places to the cushioning shell 220, so that the cover may be removed from the shell 220 without damaging the shell.
  • attachment may be made by use of Velcro (a trademark of Velcro USA Inc., Manchester, New Hampshire).
  • the thin cover may be glued, tacked or sewn to the shell 220.
  • the thin cover 215 covers the entire cushioning shell 220.
  • the cushioning shell 220 is comprised of foam.
  • the foam may be an elastomeric, cellular (including microcellular) foam or any other desirable foam.
  • the cushioning shell is comprised of a soft resilient thermoplastic polyurethane (TPU).
  • the cushioning shell is comprised of open-cell polyurethane.
  • the cushioning shell is comprised of closed cell polyolefin foam.
  • the cushioning shell is comprised of polyethylene foam which may be a high or low density polyethylene foam.
  • the hardness of the cushioning shell is much lower than the hardness of the ballistic-resistant inner shell 240.
  • the hardness of the cushioning shell is typically described by the Shore A
  • Durometer scale typically Shore A 60 and under, and even more typically Shore A 30 and under
  • Shore D Durometer scale typically Shore A 60 and under, and even more typically Shore A 30 and under
  • the outer surface 222 of the cushioning shell 220 is generally (hemi-)spherical in shape.
  • the cushioning shell may be between 3mm and 13mm thick, although it may be thinner or thicker.
  • the cushioning shell may have a density of between 3.4 lbs/ft 3 (approximately 0.016 g/cm 3 ) and 25 lbs/ ft 3 (approximately 0.4 g/cm 3 ), although it may be more dense or less dense.
  • the cushioning spacer layer 230 comprises a plurality of pads 231.
  • the pads 231 may be circular in shape or may be formed in other shapes. Multiple shapes may be used together.
  • the spacer layer may include a strip of material 233 (seen in Fig. 8) around the peripheral edge of the military helmet between the shell 220 and the hard inner shell 240 that can prevent foreign material from entering between the shell 220 and the hard inner shell 240.
  • the cushioning spacer layer is a single pad 230a defining multiple cut-outs 235a (i.e., the equivalent of multiple connected pads).
  • the spacer layer 230 is comprised of foam.
  • the foam may be an elastomeric, cellular (including microcellular) foam or any other desirable foam.
  • the cushioning spacer layer is comprised of a soft resilient thermoplastic polyurethane (TPU).
  • the cushioning spacer layer is comprised of open- cell polyurethane.
  • the cushioning spacer layer is comprised of closed cell polyolefm foam.
  • the cushioning spacer layer is comprised of polyethylene foam which may be a high density or low density polyethylene foam.
  • the cushioning spacer layer 230 has multiple layers formed from different materials. In all embodiments, the hardness of the cushioning spacer layer material is much lower than the hardness of the ballistic-resistant inner shell.
  • the cushioning spacer layer may be between 3mm and 26mm thick, although it may be thinner or thicker. As another example, the cushioning spacer layer may be between 6 and 13mm thick.
  • the cushioning spacer layer may have a density of between 3.4 lbs/ft 3 (approximately 0.016 g/cm 3 ) and 25 lbs/ ft 3 (approximately 0.4 g/cm 3 ), although it may be more dense or less dense.
  • the spacer layer 230 covers approximately fifty percent of the inner surface area of the shell 220. In another embodiment, the spacer layer 230 covers between twenty percent and eighty percent of the inner surface area of the shell. The spacer layer 230 should cover sufficient area between the shell 220 and the hard inner shell 240 so that upon most expected impacts to the helmet 210, the shell 220 does not directly come into contact with the hard inner shell 240. Regardless of the material and arrangement of the cushioning spacer layer 230, in one embodiment the cushioning material is affixed to the shell 220 and to the hard inner structure. Affixation can be done with glue, Velcro or any other affixation means.
  • the hard ballistic-resistant inner shell 240 is comprised of a ballistic-resistant fibrous material.
  • the inner shell material comprises a para-aramid synthetic fiber such as KEVLAR (a trademark of DuPont of Wilmington, DE).
  • the inner shell material comprises TWARON (a trademark of Teijin Twaron, B.V. of the Netherlands).
  • the inner shell material comprises ultra-high-molecular-weight polyethylene.
  • the hard ballistic-resistant shell 240 is affixed to the spacer layer 230. Affixation can be done with glue, Velcro or any other affixation means.
  • the hard ballistic-resistant shell is between 2mm and 20mm thick, although it may be thinner or thicker.
  • the hard inner ballistic-resistant shell 240 is between 7mm and 12mm thick.
  • the one or more innermost cushioning pad(s) 250 is comprised of foam.
  • the foam may be an elastomeric, cellular foam or any other desirable foam.
  • the cushioning pad(s) 250 is comprised of a soft resilient thermoplastic polyurethane (TPU).
  • the cushioning pad(s) is comprised of open-cell polyurethane.
  • the cushioning pad(s) is comprised of closed cell polyolefin foam.
  • the cushioning pad(s) is comprised of polyethylene foam which may be a high or low density polyethylene foam. In all embodiments, the hardness of the material innermost cushioning pad(s) is considerably lower than the hardness of the ballistic-resistant inner shell 240.
  • the innermost cushioning pad 250 is a single pad defining multiple cut-outs (i.e., the equivalent of multiple connected pads). In another embodiment, a plurality of innermost cushioning pads 250 are provided. Regardless, the single pad with the cut-outs or the multiple pads are arranged in a desired configuration and are affixed to the hard inner structure 240. Affixation can be done with glue, Velcro or any other affixation means.
  • the innermost cushioning layer may be between 3mm and 26mm thick, although it may be thinner or thicker.
  • the innermost cushioning pads may have a density of between 3.4 lbs/ft 3 (approximately 0.016 g/cm 3 ) and 25 lbs/ ft 3 (approximately 0.4 g/cm 3 ), although they may be more dense or less dense.
  • the innermost cushioning pad(s) 250 is covered by a fabric layer 260 (seen in Fig. 10).
  • fabric layer 260 is absorbent.
  • fabric layer 260 is removable from the foam pad(s) 250.
  • the flexible thin cover is made from ballistic nylon, a high denier nylon thread with a dense basket wave such as Cordura (a trademark of Invista, Wichita, Kansas).
  • the flexible thin cover is made from a Neoprene (a trademark of DuPont, Delaware) rubber (polychloroprene) fabric.
  • the flexible thin cover is made from a polyester fabric.
  • the flexible thin cover is made from non-woven fabric.
  • the thin cover may be between 0.3mm and 3.25mm thick, although it may be thinner or thicker.
  • the flexible thin cover may be between 1.0mm and 1.5mm thick.
  • the military helmet 210 is adapted to be compatible with night vision devices (NVDs), communication packages, Nuclear, Biological and Chemical (NBC) defense equipment and body armor.
  • NBDs night vision devices
  • NBC Nuclear, Biological and Chemical
  • the military helmet 10 provides an unobstructed field of view and increased ambient hearing capabilities.
  • the military helmet 210 is provided with a chin strap retention system 295 (Fig. 12).
  • the military helmet 210 is provided with an armor nape pad (not shown).
  • the armor nape pad (not shown) is provided with a cushioning outer layer, a hard ballistic-resistant inner layer, a cushioning spacer layer located between and separating the cushioning outer layer and the hard ballistic-resistant inner layer, and a cushioning pad coupled to the inside surface of the hard ballistic-resistant inner layer.
  • the outer surface of the cushioning outer layer of the nape pad and/or the inner surface of the cushioning pad coupled to the inside surface of the hard ballistic-resistant inner layer of the nape pad may be provided with a fabric layer.
  • small holes are drilled in one or both of the cushioning shell and in the anti-ballistic hard shell for ventilation purposes and/or for attaching straps or other structures.
  • the attachment holes may be covered by ballistic screws, nuts or bolts. Regardless, it will be appreciated that the size and number of holes in the anti-ballistic hard shell is kept to a minimum to limit the potential of penetration of projectiles through the holes. For purposes of the claims, a shell structure having holes for these purposes should still be considered a "continuous shell".
  • the military helmet 210 has a concave outer surface and a convex inner surface. As seen in Fig. 10, the shape of the military helmet is adapted to cover the back, top, and sides of a soldier's head without blocking vision or hearing. As such, the bottom rim of the helmet angles upward from the back of the helmet toward the front of the helmet at a first angle a, and then angles a steeper angle ⁇ at about the ear area, and then extends substantially horizontally ⁇ at the forehead area. [0079]
  • the military helmets described are particularly suited for military use although they may be used for other purposes such as, by way of example only and not by way of limitation, a protective police helmet or an explosive ordinance disposal (EOD) helmet.
  • EOD explosive ordinance disposal
  • Riot helmet 310 includes a multilayered system including an optional outermost cover 315, a cushioning outer shell 320 having a convex outer surface and a concave inner surface, a hard inner shell 340 with a convex outer surface and a concave inner surface, a cushioning spacer layer 330 located between and separating the cushioning outer shell 320 and the hard inner shell 340, and optional innermost cushioning pads (not shown) coupled to the inside surface of the hard inner shell 340.
  • the flexible thin cover 315 may be a fabric, film, foil, leather (actual or imitation) or other cover such as a ballistic nylon (a high denier nylon thread with a dense basket weave) that is used as a cover for the helmet.
  • the flexible thin cover may provide a surface for printing graphics.
  • the flexible thin cover may also protect the cushioning outer shell from damage. If desired, the flexible thin cover may extend around the periphery of the helmet to protect the periphery of the cushioning shell 320 and the cushioning spacer layer 330 and optionally the hard inner shell 340.
  • a flexible band may be used to extend around the periphery and cover the peripheral edge of cushioning shell 320, the spacer layer 330 and optionally the hard shell 340.
  • the thin cover may be between 0.1mm and 10mm thick, although it may be thinner or thicker.
  • the flexible thin cover may be between 0.3mm and 3.25mm thick.
  • the flexible thin cover may be between 1.0mm and 1.5mm thick.
  • the thin cover 315 may be attached at one or more places to the cushioning shell 320, so that the cover may be removed from the shell 320 without damaging the shell. Alternatively, the thin cover may be glued, tacked or sewn to the shell 320. In one embodiment, the thin cover 315 covers the entire cushioning shell 320.
  • the cushioning shell 320 is comprised of foam.
  • the foam may be an elastomeric, cellular (including microcellular) foam or any other desirable foam.
  • the cushioning shell is comprised of a soft resilient thermoplastic polyurethane (TPU).
  • the cushioning shell is comprised of open-cell polyurethane.
  • the cushioning shell is comprised of closed cell polyolefm foam.
  • the cushioning shell is comprised of polyethylene foam which may be a high or low density polyethylene foam.
  • the hardness of the cushioning shell is much lower than the hardness of the inner shell 340.
  • the hardness of the cushioning shell is typically described by the Shore A Durometer scale (typically Shore A 60 and under, and even more typically Shore A 30 and under), whereas the hardness of the inner shell is described by the Shore D Durometer scale.
  • the outer surface of the cushioning shell 320 is generally (hemispherical in shape.
  • the cushioning shell may be between 3mm and 13mm thick, although it may be thinner or thicker.
  • the cushioning shell may have a density of between 3.4 lbs/ft 3 (approximately 0.016 g/cm 3 ) and 30 lbs/ ft 3 (approximately 0.48 g/cm 3 ), although it may be more dense or less dense.
  • the cushioning spacer layer 330 comprises either a plurality of pads 331 that are coupled together by a thin underlay er 331a (indicated by dashed line in Fig. 16), or a single pad with multiple channels 331b (shown in Fig. 14) that define multiple pad areas 331.
  • the pads 331 may assume multiple shapes and sizes.
  • the cushioning spacer layer 330 comprises a plurality of separated pads.
  • the spacer layer 330 is comprised of a microcellular open cell urethane foam; e.g., PORON XPvD, a trademark of Rogers Corporaton, Rogers, Connecticut.
  • a microcellular open cell urethane foam e.g., PORON XPvD, a trademark of Rogers Corporaton, Rogers, Connecticut.
  • the spacer layer 330 comprises a foam that may be an elastomeric, cellular (including microcellular) foam or any other desirable foam.
  • the cushioning spacer layer 330 is comprised of a soft resilient thermoplastic polyurethane (TPU).
  • the cushioning spacer layer is comprised of open-cell polyurethane.
  • the cushioning spacer layer is comprised of closed cell polyolefm foam.
  • the cushioning spacer layer is comprised of polyethylene foam which may be a high density or low density polyethylene foam.
  • the cushioning spacer layer 330 has multiple layers formed from different materials.
  • the hardness of the cushioning spacer layer material is much lower than the hardness of the ballistic-resistant inner shell.
  • the cushioning spacer layer may be between 3mm and 26mm thick, although it may be thinner or thicker.
  • the cushioning spacer layer may be between 6 and 13mm thick.
  • the cushioning spacer layer may have a density of between 3.4 lbs/ft 3 (approximately 0.016 g/cm 3 ) and 30 lbs/ ft 3 (approximately 0.48 g/cm 3 ), although it may be more dense or less dense.
  • the cushioning spacer layer has a hardness of between 2 and 30 on the Shore A scale.
  • the spacer layer 330 covers approximately ninety- five percent of the inner surface area of the shell 320 and one hundred percent of the outer surface of the hard shell 340 (with underlayer 331a). In another embodiment, the spacer layer 330 covers between twenty percent and eighty percent of the inner surface area of the shell.
  • the cushioning material is affixed to the shell 320 and to the hard inner structure. Affixation can be done with glue, Velcro or any other affixation means.
  • Spacer layer 330d is seen in Fig. 15.
  • Spacer layer 330d may be made from any of the materials previously described with respect to spacer layer 330.
  • Spacer layer 330d is shown cut from sheet material, such that spacer layer 330d takes the form of a flower with a central area 330e and petals 330f.
  • Grooves 330g extending into, but not completely through the material of spacer layer 330d are formed in the petals and the central area and add to the flexibility of the spacer layer 330d so that it may be placed between the formed cushioning shell 320 and the formed hard shell 340 and assume a three-dimensional position with the petals 300f either touching each other or more closely spaced.
  • the hard inner shell 340 is comprised of a carbon fiber material.
  • the inner shell material comprises a para-aramid synthetic fiber such as KEVLAR (a trademark of DuPont of Wilmington, DE).
  • the inner shell material comprises TWARON (a trademark of Teijin Twaron, B.V. of the Netherlands).
  • the inner shell material comprises ultra-high-molecular-weight polyethylene.
  • the hard shell 340 is affixed to the spacer layer 330 (or 330d). Affixation can be done with glue, Velcro or any other affixation means.
  • the hard shell is between 2mm and 20mm thick, although it may be thinner or thicker.
  • the hard inner shell 340 is between 7mm and 12mm thick.
  • FIG. 17 is a perspective exploded view of an embodiment of a helmet 410 utilizing aspects of the other helmet embodiments with like parts having like numbers separated by one hundred, two hundred, three hundred or four hundred.
  • Helmet 410 includes an optional outermost cover 415, a cushioning outer shell 420 having a convex outer surface and a concave inner surface, a hard inner shell 440 with a convex outer surface and a concave inner surface, a cushioning spacer layer 43 Od located between and separating the cushioning outer shell 420 and the hard inner shell 440.
  • Helmet 410 combines aspects of previously described embodiments.
  • outermost cover 415 is provided with chin straps 495 (similar to the military helmet 210 of Fig. 12), and the cushioning spacer layer 430d is substantially the same as the alternate cushioning spacer layer 330d of the riot helmet of Fig. 15.
  • Cushioning spacer layer 430d is shown in a partly rounded configuration in Fig. 17, and when assembled, the leaves 430f will assume a configuration where they are more closely adjacent each other at their circumferences.
  • the materials and other aspects of the layers are as previously described with respect to the other embodiments.
  • Fig. 18 is a perspective exploded view of layers of an embodiment of a helmet which can be a football helmet, an ice-hockey helmet, a baseball helmet, a motorcycle helmet, a riot helmet, a military helmets and any other helmets.
  • the helmet includes an optional outermost cover 515, a cushioning outer multilayer structure 520 with at least two outer cushioning layers having different densities and different geometric layouts, a hard multilayer structure 540 located inside the outer cushioning layers, and a cushioning inner structure 550 550 inside the hard multilayer structure 540.
  • Each of the cover 515, cushioning outer multilayer structure 520, and hard multilayer structure 540 have a generally convex outer surface and a generally concave inner surface.
  • the cushioning outer multilayer structure 520 includes three cushioning layers with a cushioning outer shell 523 formed from a foam such as a microcellular urethane foam (e.g., PORON) or expanded polystyrene (EPS) foam, an intermediate springy layer 525 (e.g., a thermoplastic polyurethane-air system such as SKYDEX - a trademark of Skydex Technologies, Inc. of Englewood Colorado), and a relatively inner spacer layer 527 of foam such as a PORON or EPS foam.
  • a foam such as a microcellular urethane foam (e.g., PORON) or expanded polystyrene (EPS) foam
  • an intermediate springy layer 525 e.g., a thermoplastic polyurethane-air system such as SKYDEX - a trademark of Skydex Technologies, Inc. of Englewood Colorado
  • a relatively inner spacer layer 527 of foam such as a PORON or EPS foam.
  • the intermediate layer 525 and inner spacer layer 527 of the cushioning outer multilayer structure 520 is provided with a different geometry than the cushioning outer shell 523 and is arranged to redirect energy transmitted from the cushioning outer shell along a circuitous path.
  • the spacer layer 527 is provided with a different density than the density of the outer shell 523.
  • the outer shell 523 may have a density of between 9 and 25 pounds per cubic foot (pcf) (approximately 144 - 400 kg/m 3 ) and the inner spacer layer 527 may have a different density in that range.
  • the outer shell density is lower than the inner spacer layer density.
  • the thickness of the cushioning outer multilayer structure 520 is between 5 and 25mm. In another embodiment, the thickness of the cushioning outer multilayer structure 520 is less than 15mm. In another embodiment, the thickness of the cushioning outer multilayer structure is less than 10mm.
  • the hard multilayer structure 540 located inside the outer cushioning layers is a multilayer structure with at least two hard layers 543, 547 and at least one cushioning layer 545 therebetween.
  • the at least two hard layers 543, 547 may composite carbon fiber structures or polycarbonate, and by way of example only, the cushioning layer 545 may be structural foam such as PORON, EPS, or a liquid gel.
  • the hard layers such as carbon fiber layers 543, 547 are between 1 and 2mm thick.
  • the thickness of the hard multilayer structure 540 is between 2 and 20mm. In another embodiment, the thickness of the hard multilayer structure 540 is less than 10mm.
  • the hard multilayer structure 540 it is desirable for the hard multilayer structure 540 to be able to be bent or shaped into a shell-like shape while maintaining its ability to stop projectiles from penetrating the hard structure 540.
  • the hard layers 543, 547 are formed from ballistic resistant materials such as a para-aramid synthetic fiber or a ultra-high- molecular-weight polyethylene.
  • the cushioning inner structure 550 located inside the hard inner structure 540 includes four layers, including two cushioning foam layers 552, 554 having different densities and different geometric layouts, a sensor layer 556, and a thermal- or climate-control layer 558.
  • the two cushioning foam layers 552, 554 are similar in densities and geometry to the two outer cushioning foam layers 523, 527.
  • the sensor layer 556 may be formed from foam or other cushioning material or a soft material such as fabric and as shown is located inside the inner cushioning foam layer 527, although it may be located between layers 523 and 527, or outside foam layer 523 and under the hard multilayer structure 540.
  • the sensor layer 556 is provided with a plurality of impact sensors located about the helmet. Each sensor on the sensor layer may be self-powered, or the sensors may be powered by a single power source such as a battery (not shown).
  • the sensors may collect impact acceleration function information along multiple axes and may provide the information wirelessly or otherwise.
  • Exemplary sensors include the xPATCH sensor of X2 Biosystems Inc. of Seattle Washington, the BRAIN SENTRY sensor of Brain Sentry, Inc. of Bethesda, Maryland, the SHOCKBOX sensor of Impakt Protective Inc. of Kanata, Ontario, Canada, the CHECKLIGHT impact sensor system of Reebok, London, United Kingdom, and the INSITE sensor system of Riddell of Rosemont, Illinois.
  • the thermal-control layer 558 may likewise be formed from foam or other cushioning material and/or a soft material such as fabric and is provided as the innermost layer of the inner structure 550.
  • the thermal-control layer 558 includes a cooling fabric and a cooling bladder attached to the inside surface of the cooling fabric.
  • the thermal-control layer utilizes "passive" thermal control such as phase change materials that absorb, store and release heat. The phase change materials may be encapsulated in a polymer shell.
  • An exemplary passive thermal- control layer 558 is formed from OUTLAST of Outlast Technologies, Inc., of Golden, Colorado.
  • an "active" thermal control element such as a fan is provided in layer 558. The fan may be formed from polymeric materials and an airway may be provided to the exterior of the helmet.
  • the inner structure 550 instead of the cushioning inner structure 550 including four layers, the inner structure 550 includes three layers 552, 554 and 558 and does not include the sensor layer. In another embodiment, instead of the cushioning structure 550 including four layers, the inner structure 550 includes three layers 552, 554 and 558, and impact sensors are provided in one of the three layers. In another embodiment instead of the cushioning inner structure 550 including four layers, the inner structure 550 includes three layers 552, 554 and 556, and does not include the thermal-control layer. In another embodiment, instead of the cushioning structure 550 including four layers, the inner structure 550 includes two foam layers 552, 554, and does not include the sensor layer or the thermal-control layer.
  • the inner structure 550 instead of the cushioning structure 550 including four layers, the inner structure 550 includes two foam layers 552, 554, and impact sensors are included in one of the foam layers 552, 554. In another embodiment, the cushioning structure 550 includes at least three foam layers with the middle foam layer having a relatively higher density than the other two layers. In another embodiment, instead of the cushioning inner structure 550 including multiple layers, the cushioning inner structure located inside the hard inner structure is a plurality of innermost cushioning pads coupled to the inside of the hard inner structure as shown or described in the different embodiments of Figs. 1, 8, and 16.
  • the optional outermost cover 515 may be a fabric, film, foil, leather, ballistic nylon, or other cover.
  • the flexible thin cover may be cosmetic and may provide a surface for printing graphics.
  • the flexible thin cover may also protect the cushioning outer shell from damage.
  • the helmet is at most 50mm thick.
  • the hardness of the hard layers 543, 547 may be characterized by a hardness on the Shore D Durometer scale (typically Shore D 75 and over), whereas generally, the hardness of the material of the cushioning layer 545 between the hard layers (and the materials of the cushioning outer multilayer structure) is characterized by a hardness on the Shore A Durometer scale (typically Shore A 60 and under, and even more typically Shore A 30 and under).
  • FIG. 19a shows a cushioning outer multilayer structure 520a
  • Fig. 19b shows the hard multilayer structure 540a
  • Fig. 19c showing an inner cushioning structure 550a. No facemask is shown.
  • an outermost covering 515a is provided.
  • a cushioning outer multilayer structure 520a includes three cushioning layers with a cushioning outer shell 523a formed from a foam such as, by way of example only, a microcellular urethane foam (e.g., PORON) or EPS, an intermediate springy layer 525a (e.g., a thermoplastic polyurethane-air system such as
  • a foam such as, by way of example only, a microcellular urethane foam (e.g., PORON) or EPS
  • an intermediate springy layer 525a e.g., a thermoplastic polyurethane-air system such as
  • the intermediate layer 525a is provided with a different geometry than the cushioning outer shell 523a and is arranged to redirect energy transmitted from the cushioning outer shell along a circuitous path.
  • the spacer layer 527a is provided with a different density than the density of the outer shell 523a.
  • the outer shell 523a may have a density of between 9 and 25 pcf, and the inner spacer layer 527a may have a different density in the same range
  • only two layers of foam 523a, 527a are utilized with different densities and with different geometries such as shown in the different embodiments of Figs. 1, 8, 13 and 17.
  • three layers of foam are utilized with the middle foam layer having a higher density than the other two layers.
  • the thickness of the cushioning outer multilayer structure 520a is between 5 and 25mm. In another embodiment, the thickness of the cushioning outer multilayer structure 520a is less than 15mm. In another embodiment, the thickness of the cushioning outer multilayer structure 520a is less than 10mm.
  • the hard multilayer structure 540a located inside the outer cushioning layers is a multilayer structure with at least two hard layers 543a, 547a and at least one cushioning layer 545a therebetween.
  • the at least two hard layers 543a, 547a may composite carbon fiber structures or polycarbonate
  • the cushioning layer 545a may be structural foam such as PORON or EPS, a springy layer made from SKYDEX, a liquid gel, or another cushioning material.
  • polycarbonate layers 543a, 547a are between 1 and 2mm thick. In one embodiment, the thickness of the hard multilayer structure 540a is between 2 and 20mm. In another
  • the thickness of the hard multilayer structure 540a is less than 10mm. In one aspect, it is desirable for the hard multilayer structure 540a to be able to be bent or shaped into a shell-like shape while maintaining its ability to stop projectiles from penetrating the hard structure 540a.
  • the cushioning inner structure 550a located inside the hard inner structure 540a includes four layers, including two cushioning foam layers 552a, 554a having different densities and different geometric layouts, a sensor layer 556a, and a thermal- control layer 558a.
  • the two cushioning foam layers 552a, 554a are similar in densities to the two outer cushioning foam layers 523a, 527a (with the geometries being similar to the cushioning foam layer 523a and the springy layer 525a) .
  • the sensor layer 556a may be formed from foam or other cushioning material or a soft material such as fabric and as shown is located inside the inner cushioning foam layer 527a, although it may be located between layers 523a and 527a, or outside foam layer 523a and under the hard multilayer structure 540a.
  • the sensor layer 556a is provided with a plurality of impact sensors 557 (three shown) located about the helmet. Each sensor on the sensor layer may be self-powered, or the sensors may be powered by a single power source such as a battery (not shown).
  • the sensors may collect impact acceleration function information along multiple axes and may provide the information wirelessly or otherwise. Exemplary sensors may be those previously described with reference to Fig. 18.
  • the thermal-control layer 558a may likewise be formed from foam or other cushioning material or a soft material such as fabric and is provided as the innermost layer of the inner structure 550a.
  • the thermal-control layer utilizes "passive" thermal control such as phase change materials that absorb, store and release heat.
  • the phase change materials may be encapsulated in a polymer shell.
  • An exemplary passive thermal- control layer 558a may be as previously described with reference to Fig. 18.
  • FIG. 20 another embodiment of a cushioning inner structure 550b is shown for a helmet such as a football helmet, but not limited thereto.
  • the cushioning inner structure 550b includes two cushioning foam layers 552b, 554b having different densities and different geometric layouts.
  • Cushioning foam layer 552b which is attached to the inside of the hard layer, is shown with a main skull pad 571, and two ear pads 573a, 573b which are optionally tethered to the main skull pad 571 by tethers 575a, 575b.
  • Each of the ear areas defines a hole 576a, 576b (for hearing) and is further provided with a cut-out or depression 577a (only one shown) for an impact or acceleration concussion sensor 578 (only one shown).
  • Cushioning foam layer 552b may be provided with additional cut-outs or depressions for housing additional sensors. Thus, cushioning foam layer 552b also serves as a sensor layer.
  • Cushioning foam layer 554b is likewise shown with a main skull pad 581 and two ear pads 583a, 583b (with holes 586a, 586b) which are optionally tethered to the skull pad 581 by tethers 585a, 585b.
  • Main skull pad 581 of foam layer 554b is provided with a cut-out or depression 587 for a cooling bladder 558b.
  • the cut-out or depression 587 is shown running from the forehead area of the main skull pad 581, to the top of the head, and it further extends from the top of the head down the back of the head to the back of the neck area of the helmet.
  • the inside of the cooling bladder 558b and the foam layer 554b may be lined with another material if desired.
  • cushioning layer 554b also serves as a thermal-control layer.
  • the foam material may be selected to be the same material as discussed above with reference to other embodiments, or other materials may be used.
  • the sensors 578 and the cooling bladder 558b may be the same as previously described, or other sensors or thermal-control elements may be used.

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  • Helmets And Other Head Coverings (AREA)
  • Professional, Industrial, Or Sporting Protective Garments (AREA)

Abstract

L'invention concerne des modes de réalisation d'un casque de protection possédant une structure multicouche externe à matelassage avec au moins deux couches de matelassage de matériaux possédant des masses volumiques différentes et des dispositions géométriques différentes, une structure multicouche interne dure fixée à la surface intérieure de la structure multicouche de matelassage, et une structure de matelassage interne fixée à la surface interne de la structure multicouche interne dure. La structure multicouche interne dure est formée d'au moins deux couches espacées de matériau dur et d'une couche de matériau de matelassage entre elles. La structure de matelassage interne peut être une structure multicouche similaire à la structure multicouche externe avec au moins deux couches de matelassage de matériaux possédant des masses volumiques différentes et des dispositions géométriques différentes. La structure de matelassage interne peut comprendre des capteurs, éventuellement dans une couche indépendante, et une couche de régulation thermique. Une couverture mince souple s'étendant autour d'une surface externe de ladite enveloppe et avec ou sans motif peut être fournie.
PCT/US2015/013407 2014-02-03 2015-01-29 Casques de protection Ceased WO2015116750A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US14/171,283 2014-02-03
US14/171,283 US9578917B2 (en) 2012-09-14 2014-02-03 Protective helmets

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017079277A1 (fr) * 2015-11-05 2017-05-11 Rogers Corporation Article multicouches présentant une résistance aux chocs améliorée
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Publication number Priority date Publication date Assignee Title
WO2017079277A1 (fr) * 2015-11-05 2017-05-11 Rogers Corporation Article multicouches présentant une résistance aux chocs améliorée
GB2558121A (en) * 2015-11-05 2018-07-04 Rogers Corp Multilayer article with improved impact resistance
US10321730B2 (en) * 2017-08-09 2019-06-18 Samir Hanna Safar Impactproof head protection device

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