Protective headgear

A helmet including a shell and a support system is provided. The shell includes an outer surface and an inner surface. The support system includes a base and a plurality of hollow cells extending outward from the base. The support system substantially conforms to the shell inner surface. The cells are segmented into a plurality of regions wherein the cells within each of the regions are coupled together in flow communication via a plurality of channels extending therebetween. At least one cell within a first region is coupled in flow communication to at least one cell within a second region to enable fluid to be selectively transferred from at least some of the cells in the first region to at least some of the cells in the second region to facilitate reducing an amount of energy induced to a wearer of the helmet following an impact to the shell.

BACKGROUND

This invention relates generally to protective headgear, and more particularly, to headgear designed to facilitate reducing skull and brain injuries.

Modern headgear, including helmets, is often worn by individuals during physical activities, including sporting events and exercise, to help protect the wearer from head injuries. At least some known head protective devices are manufactured to satisfy safety and/or legal regulations set by various federal and state agencies, and/or organizations governing specific activities. For example, military helmets may be manufactured to withstand different requirements than those required by professional sports organizations, such as Major League Baseball (MLB) or the National Football League (NFL). Generally, the efficacy of all protective headgear is constantly examined to facilitate enhanced head protection for the wearer. Moreover, because brain damage is cumulative and is permanent, no corrective measure can undo damage resulting from a brain injury and as such, the focus of preventing such injuries from occurring has been elevated.

Generally, protective headgear is designed to satisfy specific requirements relating to inter alia the maximum acceleration that may occur in the center of the wearer's brain at a specified load, and/or to withstand the maximum impact that the wearer's head may be exposed to during a specific activity. Typically, during testing of at least some known protective headgear, a dummy skull equipped with a protective headgear, such as a helmet, is subjected to a radial impact. More specifically, if the wearer's head is not in motion when impacted by an object, generally the impact creates a linear acceleration and a point load (i.e., a force concentrated over a small area). Such an impact may result in a skull fracture and/or mild traumatic brain injury (MTBI). More specifically, the severity of injury to the wearer may vary depending on several factors, including the magnitude and direction of the impact. When an external impact shakes the brain inside the skull, the shaking may result in temporarily disrupting the brain from working normally by disturbing or damaging electrical, chemical, and/or anatomical function connections within the brain, which may result in MTBI.

At least some known protective headgear attempt to absorb as much of the energy transmitted by radial impact with another object, including equipment worn or used by another person, a body part of another person, the ground, and/or a structural object, and/or attempt to deflect impacts occurring at an oblique angle to the helmet. Moreover, at least some known protective headgear is designed to reduce brain concussions to the wearer. To reduce the effect of an external impact to the wearer, at least some known helmets include at least a hard outer shell, often fabricated from a plastic or a composite material, and an energy absorbing layer called a liner. Some known helmets also include an internal head-fitting structure such as a suspension webbing, a foam layer, fluid-filled bladders, and/or a padding molded to fit a specific wearer. The hard exterior plastic shells of known helmets and the interior form-fitting structures have the ability to absorb a certain amount of the impact energy induced to the wearer when the helmet is impacted by an object. Any impact energy not absorbed by the helmet is transferred to the skull of the wearer, which may result in injuries ranging from mild concussions or mild traumatic brain injury (MTBI) to severe brain damage. Helmets fabricated as such, provide some impact-absorption capacity to the wearer for impacts that are primarily radially-directed, but typically such helmets generally provide far less energy absorption for impacts induced non-radially to the helmet.

Other known helmets may include impact-absorbing compression members that compress when subjected to an impact. For example, at least some of such helmets include cells that are compressible when the helmet is pressed against the wearer's head when subjected to impact forces. At least some of the known compression cells may be filled with a resilient material, such as foam. However, depending on the size and density of the resilient material, such cells may be prone to bottoming out when compressed between the helmet and the wearer's head. Once bottomed out, the energy absorption ability of such cells is limited at best. Simply increasing the density of the compressible material and/or increasing the thickness of the cells may provide only limited benefits and may require significant increases in the overall size of the helmet. Other known compression cells are fabricated from materials that are more resilient than foam and that return to their original shape after being compressed. Generally such compression cells are hollow and expel air as they are compressed between the helmet and the wearer's head. As such, depending on the size and placement of the cells in the area of an impact to the helmet, only one or a limited amount of cells may be compressed, such that a point load, of lesser magnitude than the original impact, may still be induced to the wearer over a relatively small concentrated area. As such, the energy-absorption capabilities and benefits of known helmets including such compression cells may be limited.

BRIEF DESCRIPTION

In one aspect, a helmet is provided. The helmet includes a shell and a support system. The shell includes an outer surface and an inner surface. The support system includes a base and a plurality of hollow cells extending outward from the base. The support system is flexible and substantially conforms to the shell inner surface. The plurality of cells are segmented into a plurality of regions wherein the plurality of cells within each of the regions are coupled together in flow communication via a plurality of channels extending between the cells. At least one of the cells within a first of the plurality of regions is coupled in flow communication to at least one cell within a second of the plurality of regions to enable fluid to be selectively transferred from at least some of the cells in the first region to at least some of the cells in the second region to facilitate reducing an amount of energy induced to a wearer of the helmet following an impact to the shell.

In another aspect, a helmet is provided that includes a shell and a support system. The shell includes an outer surface and an inner surface. The support system includes a base and a plurality of hollow cells extending outward from the base. The base includes an outer surface and an inner surface. The support system is flexible and substantially conforms to the shell inner surface. The plurality of cells are segmented into a plurality of regions, wherein cells within each of the respective regions are coupled together in flow communication via a plurality of channels extending there between. The plurality of cells within at least a first and a second of the plurality of regions extend outward from the base outer surface and are between the shell inner surface and the base outer surface. At least a first cell in the first plurality of regions is coupled in flow communication to at least one cell in the second plurality of regions for selectively transferring fluid there between. The plurality of cells within at least a third of the plurality of regions extend outward from the base inner surface. At least a first of the plurality of cells in the first plurality of regions is coupled to a flow control device configured to selectively control flow independently to and from at least some cells in the third plurality of regions.

In a further aspect, a support system for use in dissipating energy induced to a protective structure is provided. The support system includes a base, a first plurality of cells, and a second plurality of cells. The base includes a first surface and an opposite second surface, and is flexible. The first plurality of hollow cells extend from the base first surface such that each of the first plurality of cells are coupled together in flow communication with each other. The first plurality of cells each extend outward from the base first surface. The second plurality of hollow cells extend outward from the base second surface such that each of the second plurality of cells are coupled together in flow communication with each other. The second plurality of cells each extend outward from the base second surface. The first plurality of cells are between the base first surface and the protective structure. At least a first of the first plurality of cells is coupled in flow communication to a flow control device configured to selectively control flow independently into and from at least one of the cells within the second plurality of cells to facilitate dissipating energy produced following an impact to protective structure.

DETAILED DESCRIPTION

Embodiments of the present disclosure relate to energy-absorption/dissipation systems implemented within various devices, components, systems, and processes to facilitate energy dissipation. In some embodiments, an energy-absorption system is implemented within support structures such as, but not limited to protective headgear, helmets, shoes, or other protective wear/clothing including baseball chest protectors, shin guards, and/or shoulder pads. In other implementations, the energy-absorption system is implemented in structures designed to absorb an impact, such as, but not limited to, crash barriers. As used herein, the term energy absorption system refers to systems that distribute energy from an impact over a larger area to facilitate dissipating the energy and to facilitate reducing impact loading induced to the wearer is substantially reduced. The embodiments described herein are exemplary and are not limited to the descriptions provided.

FIG. 1is a perspective view of an exemplary helmet10that may include an energy-absorption system (not shown inFIG. 1). More specifically, in the exemplary embodiment, helmet10is a football helmet that includes a shell12, a facemask14coupled to shell12, and a chin strap16that is selectively adjustable to facilitate securing helmet10to the head of a wearer.

In the exemplary embodiment, shell12is hardened and includes an inner surface18and an opposite outer surface20. Shell12is fabricated from a material that has properties that enable shell12to substantially resist tears and abrasion due to impacts with objects. Moreover, in the exemplary embodiment, shell outer surface20has a low coefficient of friction. In some embodiments, shell12is fabricated from a polymer material, such as, but not limited to polycarbonate, Acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), glassfiber, Aramid, TWARON®, carbonfibre, or KEVLAR®. In an alternative embodiment, helmet10may include a thin layer (not shown) extending across inner surface18that has physical characteristics that enable it to absorb some of the energy induced to helmet10as a result of an impact to helmet10. For example, such a layer may be fabricated from a polymer foam material such as EPS (expanded poly styrene), EPP (expanded polypropylene), EPU (expanded polyurethane) or other structures like honeycomb for example.

In the exemplary embodiment, facemask14includes a plurality of bars30that are each fabricated from resin-impregnated carbon fibers wrapped in KEVLAR®. Alternatively, facemask14may be fabricated from any material that enables facemask14to work in cooperation with shell12to facilitate absorbing at least some of the energy that impacts with it. In addition, facemask14and/or shell12may include other features, such as, but not limited to, vents.

FIG. 2is a partially-broken away side view of an exemplary energy-absorption system50coupled within helmet10.FIG. 3is a schematic view of energy-absorption system50.FIG. 4is a cross sectional schematic plan view of a portion of energy-absorption system50andFIG. 5is an enlarged cross-sectional schematic view of a portion of energy-absorption system50as taken along line5-5.FIG. 6is an enlarged perspective cross-sectional view of a portion of energy-absorption system50taken along area6-6. Although the present disclosure is illustrated in the context of sports equipment, and more particularly, football helmet10, it should be appreciated that numerous helmet types can utilize energy-absorption system50, and that helmet10is merely exemplary. For example, energy-absorption system50may be used with, but is not limited to being used with, military helmets, lacrosse helmets, batting helmets, hockey helmets, bicycle helmets, motorcycle helmets, construction/safety hard hats, headgear for rock or mountain climbing and/or headgear for boxers. Moreover, energy-absorption system50may be incorporated into crash barriers, outfield walls, wrestling mats, gymnastic mats, infant car seats, and/or sports equipment such as shin guards or chest protectors.

In the exemplary embodiment, system50is coupled within helmet10and is contoured to compliment helmet inner surface18. As such, in the exemplary embodiment, during use, system50is flexible and, as described in more detail below, substantially mates against, and/or is positioned in close proximity to, helmet inner surface18within helmet50. More specifically, in the exemplary embodiment, energy-absorption system50is sized and shaped to extend across substantially all of helmet inner surface18.

System50includes a base62and a plurality of hollow cells60. Cells60extend outward from base62and as described in more detail below, may be oriented in any arrangement or orientation relative to base62that enables system50to function as described herein. Because system50extends across substantially all of helmet inner surface18, system50may include cut-outs or openings53that substantially correspond to openings54and/or vents formed in helmet10.

In each embodiment, system50includes a plurality of hollow cells60that extend outwardly from base62. In the exemplary embodiment, base62is sized to enable cells60to extend across substantially all of helmet inner surface18. Base62is flexible and is formed from a plurality of layers70that are coupled together. In one embodiment, base62and cells60are formed from a flexible neoprene material. Alternatively, base62and cells60may be formed from any non-neoprene material that enables system50to function as described herein. In the exemplary embodiment, an outer layer72is coupled to an outer conformal layer74, and an inner layer76is coupled to an inner conformal layer78. Moreover, in the exemplary embodiment, outer layer72is coupled against inner layer76such that layers72and76extend between conformal layers74and78, as described in more detail below. In one embodiment, at least a portion of one layer72,74,76, and/or78, is fabricated from a material that prevents that specific layer72,74,76, and/or78, or portion of that layer72,74,76, and/or78, from bonding against the other layers70. In an alternative embodiment, base62includes more than four layers70. In another alternative embodiment, base62only includes only one conformal layer74or78, and/or may include only inner layer76or outer layer72. Layers72,74,76, and/or78may be coupled together in any orientation that enables system50to function as described herein. For example, in one embodiment, layer72is positioned adjacent to helmet inner surface18and layer74is adjacent to layer76.

In the exemplary embodiment, each conformal layer74and78is formed unitarily with cells60, such that cells60extending from each specific layer72or76are only coupled in fluid flow communication with cells60extending from that specific layer72or76and are not coupled in flow communication with cells60extending from the other layer76or72, as is described in more detail below. Moreover, in the exemplary embodiment, not all cells60extending from each layer72or76are coupled together in fluid flow communication, but rather, each specific layer72and76is defined into impact cell regions80that include cells60that are coupled together in fluid flow communication with each other, and different impact regions80are coupled together in flow communication, as described in more detail below. More specifically, in the exemplary embodiment, cells60are oriented substantially symmetrically across each conformal layer74and78, relative to helmet10. It should be noted that within cell regions80, adjacent cells60are separated by a distance D1that may vary depending on the orientation of cells60relative to helmet10. In an alternative embodiment, cells60may be coupled together in any arrangement and/or orientation with respect to each other that enables system50to function as described herein.

In the exemplary embodiment, each conformal layer74and78is molded with, and is thus formed integrally, with cells60extending from that respective layer74or78. In an alternative embodiment, cells60may be coupled to layer74or78, using any suitable coupling means including gluing and/or RF welding. In another alternative embodiment, cells60are formed integrally with layer72or76using an injection molding process. In the exemplary embodiment, cells62are all substantially identical and each has generally the same height H. Moreover, because each cell60in the exemplary embodiment is substantially circular, each has substantially the same diameter D2. Alternatively, a plurality of different-sized and/or different-shaped cells60may extend from72and/or76. For example, in some embodiments, at least some cells60are contoured at their outer ends81.

Moreover, in the exemplary embodiment, the shape, size, and orientation of each cell60with respect to either layer74and/or78, as well as the material and thickness of conformal layers74and78are variably selected to facilitate each cell60controllably buckling when subjected to an impact, to facilitate optimal fluid transfer between cells60, as described in more detail below, and to ensure that each cell60quickly returns to its original shape after being subjected to an impact. In addition, the location and number of cells60, as well as the fluid pressure in cells60are also variably selected to facilitate system50functioning as described herein, and more specifically to facilitate optimizing the response of cells60to a wide range of impact loads, regardless of the angle of the impact relative to each cell60.

In the exemplary embodiment, system50is divided into impact regions80that are spaced across substantially all of inner surface18. Specifically, in the exemplary embodiment, regions80are generally symmetrically aligned with respect to helmet10and include a pair of side regions82and83, a front region84, a rear region (not shown), and an upper region86. Regions80are not distinct and/or independent from each other, but rather regions80overlap in the exemplary embodiment. In alternative embodiments, system50may include more or less regions than are illustrated inFIG. 3. Moreover, the relative locations of regions80are variably selected to facilitate optimizing energy absorption by system50as described herein. At least some cells60within different regions80are coupled together in flow communication as described in more detail below. Furthermore, in the exemplary embodiment, cells60in conformal layers74and78are divided into the same impact regions80. Alternatively, conformal layer74may be divided into different impact regions80than conformal layer78.

A plurality of channels90extend between adjacent cells60within each region80. Channels90may extend between any number of cells60that facilitates system50functioning as described herein. More specifically, in the exemplary embodiment, within each region80, at least some channels90are arranged generally in flowpaths that extend across system to couple cells60together. In at least a portion of the exemplary embodiment, channels90are arranged in generally X-shaped patterns that couple four adjacent cells60together in flow communication. Channels90may extend between any number of cells60(i.e., at least two) and may extend in any orientation that enables system50to perform as described herein.

Channels90are coupled in sealing contact with each respective conformal layer74and/or78. In one embodiment, channels90are coupled to each conformal layer74and/or78using a silk-screening process. In another embodiment, channels90are formed integrally with each conformal layer74or78. In a further embodiment, channels90are coupled to each layer74or78using an X-Y printing machine process. In yet another embodiment, channels90are coupled to layers74or78using an adhesive process. In a further embodiment, channels90are formed using a liquid gasket process. In another embodiment, channels90are formed using a spray process. In a further embodiment, channels90are coupled to each conformal layer74or78using any process that enables channels90to couple to a layer74or78such that adjacent cells60are coupled together in flow communication. For example, in one alternative embodiment, flow tubes are coupled to a layer62to form channels90.

In one embodiment, a release agent is contained within each channel90. The release agent facilitates ensuring that channels90remain substantially unobstructed during the assembly of system50, such that adjacent cells60coupled together via channels90remain in fluid flow communication. More specifically, and as described in more detail below, in such an embodiment, during assembly of system60, the release agent ensures that adjacent system layers72and74, and/or layers76and78remain separated to define channels90. In the exemplary embodiment, the release agent is formed from a low viscous solution. In another embodiment, the release agent is any solution that performs as described herein, and more specifically, prevents the bonding together of the layers72with74, and76with78, such as, but not limited to, petroleum-based mixtures.

In the exemplary embodiment, each layer72and76is approximately the same cross-sectional size and shape as each respective conformal layer74and78as defined by an outer perimeter of each conformal layer74and78. Alternatively, layers72and76may be sized differently, and/or may have different cross-sectional shapes. In the exemplary embodiment, each layer72and76defines a plurality of fluid control devices100. In the exemplary embodiment, fluid control devices100are known as lock pockets. Lock pockets100, in the exemplary embodiment, are not all coupled together in fluid flow communication, but rather, lock pockets100are oriented and coupled together relative to regions80to facilitate operation of system50as described herein. More specifically, lock pockets100are coupled together by a plurality of lock pocket channels102. In the exemplary embodiment, lock pockets100are each substantially circular and each has a diameter D3that is less than a length L1of each respective channel90that each lock pocket100is positioned against as described herein. In an alternative embodiment, lock pockets100may have different shapes on each layer72and76, or those defined by layer72may have a different shape than those defined by layer76. Moreover, in another embodiment, lock pockets100are non-circular. As described herein, varying the volume and location of lock pockets100, relative to layers72and/or76facilitates controlling fluid flow and optimizing energy transfer and dissipation. Alternatively, channels102may be sized differently and/or may have varying or different cross-sectionals shapes and/or may include throats defined therein.

In another alternative embodiment, system50does not include lock pockets100, but rather includes a plurality of other fluid control mechanisms, such as check valves, that operate to control flow communication similarly to the lock pockets100described herein. In a further alternative embodiment, system50includes at least one fluid control mechanism in addition to at least one lock pocket100. For example, such fluid control devices may include, but are not limited to only including, mechanical devices, electro-mechanical devices, pneumatic devices, hydraulic devices, electrical devices, or magnetic devices. Moreover, in other embodiments, system50includes in the alternative to lock pockets100, and/or in addition to lock pockets100, fluid control devices such as converging/diverging throats, venturis, and/or other flow restriction/control devices formed in channels90. Furthermore, in some embodiments, a plurality of cells60are coupled in flow communication to a header, a bladder, or a manifold that is used to facilitate flow control, and in such embodiments, lock pockets100may be positioned to control flow into or from the manifold.

Each lock pocket100is positioned substantially concentrically with respect to at least one channel90extending between a plurality of cells60when each layer72and76is coupled to a respective conformal layer74and78. For example, in some locations within system50, a lock pocket100is positioned substantially concentrically with respect to a pair of channels90. Accordingly, in the exemplary embodiment, when layers72and74, and layers76and78are coupled together, lock pocket channels102are substantially centered, and extend, between adjacent cells60and/or extend between cells60in different regions80, such as cells60in side regions82and83. Alternatively, lock pockets100may be positioned anywhere relative to channels90that enables lock pockets100and system50to perform as described herein.

In the exemplary embodiment, lock pockets100and lock pocket channels102are formed within each layer72and/or76by coupling polymers to each layer72and76. In one embodiment, the polymers are coupled via a radio frequency (RF) welding process, wherein the polymers are positioned across each layer72and/or76in desired locations prior to each layer72and/or76being coupled to a respective conformal layer74and/or76. In one embodiment, each layer72and/or76is coupled to a respective conformal layer74and78with a lamination process. Specifically, in the exemplary embodiment, prior to either layer72or76being coupled to a respective layer74and78, an adhesive material is applied to layer72or76such that the adhesive material extends substantially across that layer72or76between lock pockets100and lock pocket channels102.

When a layer72or76is coupled to a respective conformal layer74or78, that specific layer72or76mates in sealing contact with areas of that conformal layer74or78that extend between adjacent cells60, and around an outer perimeter of each hollow cell60. More specifically, when layer72or76is coupled to layer74or78, lock pockets100and lock pocket channels102are properly oriented relative to cells14, and are defined against that conformal layer74or78and between an outer surface of each layer72and76and a lower surface of each conformal layer74and78. The release agent prevents each layer72and76from sealing against a respective conformal layer74and78in areas defined by channels90, such that, as described in more detail below, fluid flow between layers72and74, and76and78is only possible through channels90.

In an alternative embodiment, system50includes only one layer72or76and conformal layers74and76are coupled to the same base layer72or76. In such an embodiment, lock pockets100may be defined between portions of each conformal layer74or78and the base layer72or76, or may be formed using channels or flow passageways90that are coupled to the base layer72or76, for example.

In each embodiment, lock pockets100and lock pocket channels102are arranged in a pre-determined or programmed pattern that is variably selected to meet a user's requirements and in a pattern or arrangement that facilitates optimizing flow control and energy transfer. More specially, the pattern of lock pockets100is selected to facilitate control of inflation and deflation of cells100when system50and more specifically, helmet10is subjected to an impact130, and/or when system50is subjected to an impact from movement of the wearers head within helmet10. Controlling the inflation and deflation of cells60facilitates transferring energy130induced to helmet10at the point of impact, by selectively transferring energy132via fluid flow through cells60and channels90until the energy induced to helmet10is dissipated. More specifically, and as is described in more detail below, when helmet10is subjected to an impact130, the array of cells60enables the impact load130induced to helmet10to be distributed132across helmet10in a manner such that the force of the impact loading130is offset and is generally equalized by the exchange of fluid pressure transferred within cells60. Generally, and as described in more detail herein, lock pockets100selectively control the inflation and deflation of at least some cells60in response to impact loading130to facilitate minimizing the biomechanical effects of a helmet impact to the brain of the user.

In the exemplary embodiment, as best seen with respect toFIG. 3, lock pockets100are oriented such that fluid flow communication via channels90between impact cell regions80is controlled when helmet10is subjected to an impact130. The relative arrangement is variably selected, based on a plurality of factors, including, but not limited to the physical demands of the wearer, and to ensure that system50provides the user with varying degrees of control and comfort, without sacrificing helmet stability or safety to the user. Moreover, the relative size and location of lock pockets100and lock pocket channels102are variably selected to facilitate operation of system50. For example, in the exemplary embodiment, to facilitate optimizing control of fluid transfer between different impact regions80and different cells60, the size and location of lock pockets100used with cells60in layer74is different than the size and location of lock pockets100used with cells in layer78.

Generally, cells60within each region80are coupled in flow communication to each other via channels90. Moreover, in the exemplary embodiment, at least some individual cells60or groups of cells60in each region80are coupled in flow communication with cells60in an adjacent different region80. For example, in the exemplary embodiment, at least some cells60in side region82are coupled in flow communication with cells60in adjacent impact regions84and86, and the rear region. In addition, at least some cells in each region80, other than region86which is coupled in flow communication to cells60in the rear region and in regions82,83, and84, are coupled in flow communication with cells60located in diametrically opposite regions. For example, in the exemplary embodiment, cells60in region82are coupled in flow communication with cells in region83, and/or cells in region84are coupled in flow communication with cells in the rear region. Furthermore, in the exemplary embodiment, as described in more detail below, at least some cells60in each region80are also coupled to lock pockets100used to control fluid flow to cells60in other regions80.

Lock pockets100are positioned within predefined areas of system to selectively control flow communication from at least some cells60in regions80to at least some cells60in other regions80. The orientation of cells60, lock pockets100, channels90and/or102, and the relative orientation of impact cell regions80may be the same or different between the system outer portion (i.e., that portion of system50formed by layers72and74) as compared to the inner portion (i.e., that of system50formed by layers76and78). Any relative orientation of cells60, lock pockets100, channels90and/or102, and cell regions80may be used that enables system50and helmet10to function as described herein.

In the exemplary embodiment, at least some cells60in impact regions80are coupled in flow communication with lock pockets100used to control flow with cells60in layer74and/or78. For example, in the exemplary embodiment, as illustrated inFIG. 7, at least some cells60in side region82are coupled in flow communication with lock pockets100used to control flow to some cells60in layer78that are in region83. Moreover, in the exemplary embodiment, at least some cells60in region83are coupled in flow communication with lock pockets used to control flow to some cells60in layer78that are located in region82. Likewise, cells60in region84are coupled to lock pockets100used to control flow to some cells60in layer78in the rear region, and cells60in the rear region are similarly coupled to lock pockets100used to control flow to some cells60in layer78that are in region84. In the alternative or in addition, at least some cells60extending within layer74and/or78could be coupled to lock pockets100used to control flow to other cells60in the same layer74and/or78.

Moreover, in other embodiments, at least some cells60in layer78could be coupled to lock pockets100used to control flow to cells60in layer74. Furthermore, in some embodiments, at least some cells60could be coupled to multiple lock pockets100used to control flow to cells60in either layer74and/or layer78, and/or could be coupled to lock pockets100used to control flow to cells60located in the same region80. Any relative orientation of cells60, lock pockets100, channels90and/or102, and cell regions80may be used that enables system50and helmet10to function as described herein. In at least some embodiments, at least some cells60extending from layer74and/or78include a support material (not shown) contained therein. More specifically, in the exemplary embodiment, the support material is inserted into specific cells60during fabrication of system50. In such embodiments, the support material is not coupled to any layer60, but rather is merely contained within each cell60and may “float freely” or shift therein.

Moreover, because the support material is not coupled any layer60, the support material does not affect inflation or deflation of cells60, but rather facilitates energy dissipation across system50. The support material can be formed of a variety of materials, including open-celled or closed-celled foam, rubberized material, polyurethane, gels, fluids, and/or combinations of materials, including non-Newtonian fluids. Any support material may be used that is resiliently deformable to some extent and that is capable of flexing and/or deflecting substantially independently of the deflection of cells60. In some embodiments, the support material may be a gel or fluid that is injected into cells60. Alternatively, the support material may have any shape that enables system50to function as described herein, including for example, a cross-sectional shape that is different than a cross-sectional shape of cells60. In another embodiment, the support material may be formed into a plurality of pellets that are inserted into cells60. In a further embodiment, the support material may be formed into a honeycombed shape. Alternatively, any support material, having any shape, including a plurality of different shapes, may be inserted into cells60, that ensures that system50functions as described herein.

In the exemplary embodiment, base62also includes at least one inflation/deflation valve (not shown) that extends from base62. In the exemplary embodiment, each layer74and78includes an inflation/deflation valve that is coupled in flow communication to lock pockets100and cells60to enable fluid to be selectively injected into, or discharged from, system50. More specifically, each inflation/deflation valve enables the fluid pressure within system50to be selectively adjusted. In one alternative embodiment, system50is a closed system that does not include an inflation/deflation valve. In another alternative embodiment, system50includes more than two inflation/deflation valves.

In the exemplary embodiment, the working fluid supplied to system50is air. In an alternative embodiment, the working fluid may be any other working fluid that that enables system50to function as described herein, including, but not limited to, other gases, fluids, or liquids. It should be noted that the working fluid used in the outer layers72and76, may be different than the working fluid used in the inner layers74and78, and in some embodiments, system50may include more than one inflation/deflation valve. For example, in such an embodiment, the radially outer layers72and76may contain a non-Newtonian fluid or a glycol fluid, while the radially inner layers74and78may contain air, or vice-versa. The working fluid may be variably selected to facilitate optimizing operation of system50.

During use, in the exemplary embodiment, system50uses air as the working fluid, and initially system50is inflated by introducing air through the cell valve(s) into cells60and lock pockets100. In one embodiment, cells60extending from layer74are initially inflated to a higher pressure than cells60extending from layer78. Cells60extending across each respective layer74and78are pressurized to approximately the same operating pressure across that specific layer74or78, although in some embodiments, cells60in layer74may be pressurized differently than cells in layer78. In one embodiment, as each cell60is inflated, cells60have a generally circular cross-sectional profile. In an alternative embodiment, at least some cells60may have a non-circular cross-sectional profile. Moreover, cells60extending from layer74may have a different cross-sectional profile than cells extending from layer78. Moreover, cells60may have any shape, size, or contour, within either layer74and/or78, including the use of multiple-shaped, sized, and/or contoured cells60within the same layer74and/or78that enables system50and helmet10to function as described herein.

After the user dons helmet10, the fluid pressure of cells60may be varied based on comfort and/or helmet immersion requirements, and is adjustable by either adding additional air, or by opening at least one inflation/deflation valve to decrease the operating pressure in cells60. Moreover, changing the fluid pressure of cells60may facilitate ensuring helmet10conforms to the wearer's head. More specifically, as cells60are inflated, in the exemplary embodiment, adjacent cells60typically contact each other, such that cells60form a generally continuous, and highly displaceable, protective surface that is highly conformable to the wearer and such that cells60in layer74are positioned substantially in contact against helmet inner surface18.

It should be noted that when a user dons helmet10, system50substantially conforms to the user's head resulting in a comfortable fit of helmet50to the user's head. Moreover, because cells60can be fabricated with a relatively low profile, helmet10is approximately the same size as, or no larger than, a conventional helmet, without the risk of cells60bottoming out during use.

When all of the cells60are inflated together, which is normally the case, the sides of adjacent cells60generally contact each other and form a generally continuous, energy-absorption system that facilitates reducing the concussive effects of impacts induced to helmet10. Moreover, in the exemplary embodiment, because system50is cellular, system50is flexible and resilient under all types of impact loading while providing comfortable protective headgear to the wearer. Furthermore, the cellular design of system50enables impact loads130induced to helmet10to be distributed132generally across the entire helmet10, such that energy resulting from the impact loading is dissipated over a large area.

In the exemplary embodiment, after the fluid pressure within cells60is substantially equalized, each cell60in each layer74and78contains approximately the same fluid pressure. Moreover, in the exemplary embodiment, as air is supplied to cells60, air is also introduced into lock pockets100through channels102. More specifically, as air is introduced into lock pockets100, the fluid pressure within pockets100is increased. Because each pocket100is positioned substantially concentrically with respect to channels90, increasing the pressure within pockets100increases an amount of force induced to each adjacent channel90. More specifically, as force is applied to channels90, flow communication is stopped between those cells60coupled together by those respective channels90. In the exemplary embodiment, the cells60coupled together by channels90may be in different regions80and may not be immediately adjacent to one another. As such, in the exemplary embodiment, lock pockets100may control fluid flow between different impact cell regions80, as well as between cells60. Moreover, in the exemplary embodiment, the fluid pressure within lock pockets100may not be sufficient to stop flow communication between the cells90until a user has donned helmet10. Accordingly, fluid flow between cells60across layers72and76may be at least partially limited and controlled by lock pockets100.

During use, when helmet10is subjected to an impact force130, a portion of the energy induced to the helmet10is absorbed and distributed by shell12and the remaining energy is induced inwardly towards the wearer. Cells60that are adjacent to the impact loading130induced to the helmet10, are collapsible in response to the impact. Specifically, each cell60is adapted to resist an impact applied to it during the initial phase of the impact, and then each deliberately yields to permit the fluid contained in that cell60to distribute132the impact loading130through a plurality of other cells60in the same region and in other regions80such that the energy induced to helmet10is dissipated. More specifically, as cells60are initially collapsed, fluid within cells60is initially discharged through channels90into other cells60within the same region. Fluid is also discharged from cells60located in the region80immediately adjacent the impact loading130into cells in adjacent regions80and into lock pockets100and cells60located in non-adjacent regions80of system50. Lock pockets100will limit at least some of the fluid transfer, as described herein.

For example, when an impact130is induced to a side of helmet10, as is shown inFIG. 3, the loading130induced to cells60in layer74is initially distributed133to adjacent cells60coupled in flow communication to the impacted cells60and within region82. Fluid is then discharged from region82into cells60in cells60in layer74in the rear region and in front region84and upper region86. A portion of fluid is also discharged into cells60extending from layer74in region83, as well as into lock pockets100that control flow into and from cells60located in layer78and within region83. Such fluid transfer facilitates dissipating the impact energy130induced to helmet10, through system50.

In addition, depending on the magnitude of the force130induced to helmet10, cells60in layer78may also be compressed against the wearer's head. If the impact130exceeds a predetermined magnitude, cells60in layer78will compress and fluid contained therein will be discharged initially into cells60within that region80. Subsequently, fluid will then be discharged into cells60in other regions80as described above. The orientation and arrangement of lock pockets100controls fluid transfer across helmet10within layers74and78. For example, depending on the relative placement and orientation of lock pockets100and cells60within outer layers72and74, relative to lock pockets100within inner layers76and78, and depending on the magnitude and location of impact130induced to helmet10, the same or a different number of cells60in outer layer74may compress, as compared to the number of cells60compressing within inner layer78. In the exemplary embodiment, cells60quickly return to their original shape as fluid rapidly refills cells60that were initially compressed. As such, after the initial transfer of energy, i.e., fluid discharge, each cell60is then ready to accept and to attenuate additional impacts or energy being dissipated from region83.

The initial inflation of lock pockets100in an impact region80that is opposite the region80initially impacted, facilitates extending the time required to stop the momentum of the wearer's skull by controlling fluid flow from cells60in the event that the wearer is subjected to a second impact shortly after the first impact130is induced to helmet50. For example, in the exemplary embodiment described above, depending on the magnitude of the impact130initially induced to helmet50, the wearer may contact another player or the ground in a region80opposite the region82(in the exemplary embodiment described above) initially impacted. Moreover, depending on the magnitude of the impact130, the wearer's skull may be forced towards the side of helmet opposite impact130(i.e., towards region83in the exemplary embodiment). The pressurization of lock pockets100facilitates ensuring that cells60located in such regions80remain temporarily pressurized to enable system50to function as described herein. More specifically, in the exemplary embodiment, impact130may cause the wearer to fall towards the ground such that helmet50contacts the ground along region83. Moreover, if the wearer's skull is forced towards the helmet along region83, lock pockets100ensure cells60are inflated to facilitate extending the time required to stop the momentum of the wearer's skull, and thus facilitates reducing the energy induced by impact130. Furthermore, inflation of lock pockets100in response to the initial impact130as system50is dissipating the initial impact loading130, facilitates enhanced flow control from cells60and thus facilitates reducing the likelihood of coup contrecoup injuries to the wearer.

During a collision, as is known, an object experiences a force for a given amount of time that results in its mass undergoing a change in velocity. Under the impulse-momentum theorem, force and time are inversely proportional, and as such, to facilitate reducing the effect of the force on the object in the collision, the time should be increased. System50enables helmet10to facilitate reducing the effects of an impact130to the wearer by extending the time required to stop the momentum of the wearer's skull against the helmet10and opposite the impact130.

It should be noted that fluid transfer between the rear region and front region84is similar to that described here for transfer between side regions82and83. In the exemplary embodiment, an impact to upper region86is dissipated through cells60within upper region86and then through all of the other impact regions80. Moreover, in the exemplary embodiment, cells60in upper region86may also be coupled to lock pockets100used to control flow to cells60in other impact regions80. Fluid transfer and venting enables system50to manage impact loading and to distribute energy from an impact130over a larger area of helmet10as opposed to inducing it to the wearer's head. As such loading can be substantially equalized across helmet10until the energy is fully dissipated. In the exemplary embodiment, the compressive ability of cells60, combined with the orientation of cells60in layers74and76, enables impact loading induced from helmet shell10to be absorbed over at least 80% of the cell height H. The orientation and arrangement of lock pockets100ensures at least some cells60remain temporarily pressurized and facilitates preventing cells60from “bottoming out” when cells60are compressed. Furthermore, cells60are durable and exhibit consistent impact-absorption even after repeated impacts to helmet10.

In some embodiments, helmet10may include at least one device mounted therein, such as but not limited to a strain gauge and/or a radio frequency identification (RFID) chip, to facilitate measuring an amount of impact induced to helmet10. System50overcomes the limitations of conventional helmet support systems. Specifically, the cellular structure of system50overcomes limitations inherent in energy absorption systems that utilize foams or other similar materials and/or structures, and is different from other air systems previously used in energy management systems. Moreover, system50is advantageous in that it provides multiple customization options, including, for example, the selection and alteration of the properties of material from which it is fabricated, the thickness of the cell walls, the density of cell material, the geometry of the individual cells, the orientation of the cells relative to each other or between different layers, the fluid viscosity, amount, and volume of fluid in the cells, and/or the size, configuration, relative location, and number of lock pockets, channels, and/or cells. By variably selecting and adjusting these properties, in coordination with each other, system50can be customized to facilitate providing a more robust functional range, depending on the particular application to which system50is to be used, than has been possible with known system. Furthermore, by variably selecting and coordinating the aforementioned properties, system50can be easily tailored to optimize energy absorption from different impact energy levels.

The above-described energy absorption system provides a user with protective headgear that is selectively and dynamically controllable to facilitate increasing stability, comfort, and impact protection to the user. More specifically, each energy absorption system includes at least one conformal layer that includes a plurality of cells extending therefrom, wherein each cell extending from the conformal layer is coupled in flow communication with other cells extending from that conformal layer. Furthermore, each energy absorption system also includes at least one layer that defines a plurality of lock pockets therein that facilitate selectively controlling fluid flow communication between at least some of the cells within the energy absorption system. In addition, the lock pockets facilitate preventing the cells from bottoming out when subjected to an impact, and thus facilitate extending the time required to stop the momentum of the wearer's skull, following an impact to the helmet. Furthermore, the lock pockets facilitate preventing a plurality of cells from deflating, in the event that an individual cell is punctured. As a result, an energy absorption system is provided which facilitates increasing the impact protection provided to a user in a cost-effective and reliable manner.

Exemplary embodiments of impact absorption systems are described above in detail. Although the impact absorption systems are herein described and illustrated in association with a football helmet, it should be understood that the present invention may be used to provide impact protection and/or energy absorption in a plurality of other uses. Moreover, it should also be noted that the components of each energy absorption system are not limited to the specific embodiments described herein, but rather, aspects of each energy absorption system method may be utilized independently and separately from other methods described herein.