Protective headgear, impact diffusing systems and methods

An impact diffusing system for protecting a user's head includes a headpiece cage coupled to a thoracic framework. In one aspect, the headpiece cage includes at least two support bars, a plurality of rigid bars surrounding at least a portion of the forehead, top, and sides of the head, and a face mask that encloses at least a portion the user's face. The thoracic framework covers at least a portion of a chest, upper back, and shoulders of the user, and the thoracic framework is attached to the support bars of the headpiece cage in a manner that prevents movement of the headpiece cage relative to the thoracic framework. In another aspect, the system includes a helmet component (formed of e.g., carbon fiber) coupled to a thoracic cage, wherein the helmet component is a solid, unitary piece that surrounds the top, back, and sides of the user's head.

FIELD OF THE INVENTION

The present invention generally relates to an impact diffusing system for protecting the head of a user of the system. More specifically, the present invention relates to an impact diffusing system that includes a helmet portion attached to a thoracic portion in a manner that prevents the helmet portion from moving relative to the thoracic portion.

BACKGROUND

The present invention is useful in sports, such as, without limitation, football (i.e., American, Australian and Canadian football), soccer, rugby, field and ice hockey, lacrosse, boxing and automotive and motorcycle racing. Additionally, the invention may find application in non-sporting activities such as military and spacecraft activities, in which bodily contact is common or the risk of collision or accident is high.

In such activities there may be a high risk of head injuries such as traumatic brain injury (TBI), as well as injuries to the neck, back, and spine. TBI is defined as damage to the brain resulting from external mechanical force, such as rapid acceleration or deceleration, impact, blast waves, or penetration by a projectile, that disrupts the normal function of the brain. TBI can result when the head suddenly and violently hits an object, or when an object pierces the skull and enters brain tissue. Immediate symptoms of a TBI can be mild, moderate or severe, depending on the extent of damage to the brain. Mild cases (mild traumatic brain injury, or mTBI) may result in a brief change in mental state or consciousness, while severe cases may result in extended periods of unconsciousness, coma or even death.

The American Society of Test and Materials (ASTM) recommends that protective headgear be worn 100% of the time to reduce the risk of TBI in most high risk activities such as those mentioned above. While various attempts have been made to make improved protective helmets, there remains a need for effective and improved protective headgear for use by various recreational, military and professional users, including both children and adults. Such headgear should be capable of substantially lessening the risk of TBI and neck, spine and back injury caused by a blow or force applied to the head, and the incidence of TBI (e.g., expressed as a percentage in a population of users) as compared to previously used helmets and protective headgear.

SUMMARY

In a broad example, the present invention is directed to methods and apparatus for preventing or reducing the severity of traumatic brain injury (1BI), neck, spine and/or back injury, through the use of protective headgear which is not supported, or is structured not to be substantially supported, by the wearer's head. Thus, in a particular example, the present invention is drawn to a protective headpiece comprising a helmet portion having an interior surface, an exterior surface and preferably a face mask component. The exterior surface of the helmet portion preferably comprises an outer protective shell, such as one including a durable material such as a resilient, impact-resistant polymer. By “resilient”, “resilience” or like words is meant capable of withstanding shock without permanent deformation or rupture. Such materials, which are preferably strong and lightweight, may include any suitable polymer such as, without limitation, a polycarbonate, a carbon fiber material, a polyester or a mixture of one or more of these materials. The majority of football helmets are made using a polycarbonate component.

In other examples, the exterior surface of the helmet portion may comprise a “soft” shell, such as a viscoelastic polymer component covering a hard shell component underneath, to reduce the force experienced by the wearer. Such viscoelastic polymers may include “memory foams” such as low-resilience polyurethane foam. If present, the soft shell component may in some cases be designed as an outer covering which can be affixed in place to a harder, resilient shell using a hook and loop type fastener, such as a VELCRO® fastener.

In one example, the helmet portion of the present invention is structured so that the inner surface thereof makes no direct contact, or minimal direct contact, with the wearer's head during use. In preferred embodiments, the inside surface of the helmet portion lacks any retaining stop, protrusion, projection, item of padding or other feature that is structured or effective to substantially restrict rotational, vertical, or horizontal movement of the wearer's head within the helmet component during use. In this way, the wearer may move the head within the helmet portion without the helmet portion itself moving. By “head” is meant the cranium and/or the cranium and the facial bones, but is not meant the mandible alone. The minimization or absence of direct contact between the helmet portion and the wearer's head lessens the likelihood, particularly when used in conjunction with the mechanism transferring impact force to a thoracic portion of the system (to be described below), that an impact received by the outer shell of the helmet portion will be directly transmitted to the head or brain of the wearer without attenuation. For instance, in some examples, the helmet portion is adapted to leave sufficient space between the inner surface of the helmet portion and the outer surface of inner headgear (described below) to permit the wearer to move his or her head substantially freely up and down and side to side within an angular range. The space between the inner surface of the helmet portion and the outer surface of the inner headgear may average, for example, about 0.5 mm, or about 0.75 mm, or about 1 mm, or about 1.5 mm, or about 2 mm, or about 0.5 cm, or about 1 cm, or about 1.5 cm, or about 2 cm, or about 2.5 cm, or about 3 cm, or more. The vertical angular range of head movement is defined herein with respect to a horizontal plane parallel to the ground and including a line passing through the eyes when the user is looking straight ahead. Such freedom of head movement (i.e. up and down) may be up to about 75 degrees, or about 70 degrees, or about 65 degrees, or about 60 degrees, or about 55 degrees, or about 50 degrees, or about 45 degrees, or about 40 degrees, or about 35 degrees, or about 30 degrees, or about 25 degrees, or about 20 degrees, or about 15 degrees. Vertical angular ranges of head movement may be independently determined and different for head movement in the “up” direction and head movement in the “down” direction.

The horizontal angular range of head movement is defined herein with respect to the sagittal plane of the body. Such head movement (i.e. left and right of center) may be up to about 90 degrees, or about 85 degrees, or about 80 degrees, or about 75 degrees, or about 70 degrees, or about 65 degrees or about 60 degrees, or about 55 degrees, or about 50 degrees, or about 45 degrees, or about 40 degrees, or about 35 degrees, or about 30 degrees, or about 25 degrees, or about 20 degrees, or about 15 degrees. Horizontal angular ranges of head movement are generally substantially identical, but may be independently determined and different for head movement in the “left” direction and head movement in the “right” direction.

In the present application unless otherwise indicated, each and every range of values (including degrees, angles, distances and the like) stated in this specification, including the claims, are intended to specifically include every point and subrange within the entire expressly specified range and not just the endpoint(s). For example, a range stated to be from 0 to 10 is intended to disclose all whole numbers between 0 and 10 such as, for example 1, 2, 3, 4, etc.; all fractional numbers between 0 and 10 to two significant figures, for example 1.5, 2.3, etc.; and the endpoints 0 and 10, as well as all subranges having these numbers as endpoints (such as the subranges “3 to 5” and “2.3 to 7.1”). Similarly, ranges expressed as “up to”, “at least”, “greater than” (or less than) a given value means the range of values extending between that value and, depending upon the context, the highest value possible or lowest value possible such as 100% (or 0%) when expressed as a percentage, or 360 or 0 when expressed as an angle. Such subranges also include all whole and fractional numbers to two significant figures between the given value and the highest (or lowest) possible value, as appropriate.

In preferred examples of the present invention, the system of the present invention comprises separate inner headgear, which may be a “soft”, preferably padded, hat component, closely fitting the wearer's head. The inner headgear is lightweight and may be comprised of, for example, a polymeric material having a cushioning property. In some examples the inner headgear may be firmly secured to the wearer's head using, for example, one or more preferably well-padded chin straps. The inner headgear may include padding comprising a forehead component to prevent injury to the forehead resulting from a blow that would otherwise force the face against the facemask of the helmet portion. The inner headgear is structured and designed to function together with the helmet portion so as to allow a range of motion for the wearer, thereby permitting wearers to move the head and inner headgear independently of the outer helmet portion to adjust their view within a range of vision while wearing the protective headgear apparatus of the present invention. Thus, in preferred embodiments, the outer surface of inner headgear lacks any retaining stop, protrusion, projection, item of padding or other feature that is structured or effective to substantially restrict rotational, vertical, or horizontal, or other movement of the wearer's head within the helmet component during use.

In some preferred examples, at least a portion of the outer surface of the inner headgear is substantially smooth and may be at least partially coated with a material having low friction, such as a material comprising polytetrafluoroethylene (PTFE), sold under the trade name TEFLON®. In some of these preferred examples, at least a portion the interior surface of the helmet portion may also similarly be at least partially coated with a material having low friction (e.g., PTFE). When the wearer experiences a blow to the helmet portion, the head and inner headgear may move independently of the outer helmet portion with lower friction and thus greater ease than if one or both surfaces were not coated with the low friction material. In some examples, the inner surface of the helmet portion may be at least partially covered with a “skin” that may be substantially smooth, thereby permitting the inner headgear to slide relative to the interior part of the helmet portion when a blow is experienced.

As described above, in important examples, the helmet portion and the inner headgear are structured and fitted in a manner such that a narrow space or gap is maintained between the inside of the helmet portion and at least a substantial part of the outer surface of the inner headgear during normal circumstances. This space may average, for example, about 0.5 mm, or about 0.75 mm, or about 1 mm, or about 1.5 mm, or about 2 mm, or about 0.5 cm, or about 1 cm, or about 1.5 cm, or about 2 cm, or about 2.5 cm, or about 3 cm, or more. Very preferably the average value of the space or gap is the smallest necessary to permit the wearer to be able to move the head and inner headgear independently and freely within the helmet portion without undue effort, while at the same time preventing the head from “rattling” against the inner walls of the helmet portion when the helmet portion receives a blow.

Preferably, the helmet portion has a wider, and optionally higher, face opening than a conventional football helmet. Since the helmet portion makes little or no direct contact, or only minimal direct contact, with the inner headgear, and is preferably sized to maintain a gap between the inner headgear and the helmet portion, the helmet portion may be larger than a conventional football helmet in some examples. For e.g., sports applications the helmet portion may preferably comprise a face mask component, such as, without limitation, a metal or polymer-coated metal “birdcage” type face mask component similar to those in current use. Preferably, the face mask component will be larger than conventional faceplates to accommodate the helmet portion's larger face opening in some examples of the present invention.

Preferably the helmet component is structured to provide ventilation to the head; particularly to the back of the head and/or neck between the collar of the thoracic portion and the lower margin of the helmet outer shell. In these embodiments the helmet portion itself may have a plurality of voids or vents defined in the back and/or sides of helmet outer shell, preferably penetrating through the inner surface of the helmet portion. These voids or vents permit fresh air to cool the head and also provide sweat and water vapor to escape entrapment on the inner surface of the helmet portion. Also, when the helmet portion and thoracic portion are joined, a gap may preferably be defined between the lower margins of the helmet component and the collar of the thoracic portion also permitting heat and sweat to escape from the head under the posterior sections of the helmet.

In important examples of the present invention, the helmet portion is either permanently or (preferably) removably affixed to a thoracic portion. Unless indicated otherwise expressly, it will be understood that the term “thoracic portion” refers to a protective piece of equipment comprising a shock absorbing pad material with a hard outer covering, such as a hard polymeric covering. As used in this specification, the protective equipment denoted the “thoracic portion” substantially covers the top portion of each of the two shoulder joints. As used herein, the shoulder joint comprises the part of the body where the humerus attaches to the scapula, the head sitting in the glenoid cavity, and is synonymous with the glenohumeral joint. The term “shoulder” or “shoulder(s)”, as used herein, means the shoulder joint and nearby structures, but excludes the neck, the portion of the clavicle that makes contact with the spine, or any portion of the spine. The thoracic portion of the present invention is thus adapted to cover at least the top portion of the wearer's shoulders. Additionally, the thoracic portion comprises a rigid framework to which the helmet portion is attached.

As discussed above, the helmet portion is made to function as a strong unitary engineered assembly with the thoracic portion, thereby transferring impact force applied to the helmet portion to the shoulders and/or body rather than the head, neck and/or spine. As indicated below, in certain embodiments the helmet portion may comprise a headpiece cage skeleton comprising a plurality of support bars which may be incorporated as part of a helmet, attached to a conventional helmet, or to which an outer shell comprising a durable material, such as a hard polymer covering at least a portion of an outer surface of the headpiece cage, is fixedly attached. Thus, in preferred examples, the helmet portion is fabricated to contain a plurality of integral support bars or “pillars” that connect the helmet portion to the thoracic portion and support the helmet during use. The term “pillars” as used herein refers to a vertical structure that extends between, and is coupled to, the helmet portion and the thoracic portion. It will be understood that, a “support bar” may act as a pillar when it connects the helmet portion of headpiece cage to the thoracic portion. The pillars may be narrow, or elongated, or any width in between, and may extend along any width of the space between the helmet portion and the thoracic portion. The pillars may be located at the back, sides and/or front of the helmet. For example, there may be four pillars, with one located in the front, one in the back, and one on each side of the helmet portion. In some examples there may be three pillars; preferably in such examples either a front pillar or a back pillar is positioned substantially on the sagittal plane, and side pillars are located on the sides above the shoulders and near (or slightly anterior to or posterior to) the coronal plane. In other examples there may be more or less than four pillars.

In certain embodiments of the invention a pillar may not be located at the front of helmet portion. For example, one embodiment of the invention comprises two lateral pillars, extending downward from the helmet portion to the thoracic portion approximately along the coronal plane, with one lateral pillar positioned on each of opposing sides of the wearer's head when in use. The invention may comprise one or more pillar positioned posterior to the lateral pillars, for example, in a preferred embodiment two posterior pillars are positioned posterior to the lateral pillars, and are connected to the helmet portion at a position to the right and to the left, respectively, of the medial plan of the wearer's head when the invention is in use. These posterior pillars extend from the helmet component in a direction simultaneously downward, laterally and posteriorly to connection points on the rear shoulders or upper back of the thoracic portion.

The pillars are strong enough to absorb at least a portion of the force transmitted by a direct impact to the helmet portion. The pillars may be manufactured using, for example, a suitably strong and lightweight material, such as one or more of titanium, a titanium alloy, a non-titanium metal, a nanostructured ceramic, a nanostructured metal or metal alloy, a thermopolymer, or a carbon polymer. In some instances, but not invariably, the pillars are wholly or partially coated with a polymeric coating. Preferably the pillars are integrated into the helmet portion as part of the structure of the helmet (e.g., during the manufacturing process), such as through an engineered network connecting the pillars within the helmet portion to help diffuse and distribute impact forces throughout the helmet portion into each of the pillars and thereby evenly transfer the force to the thoracic portion.

In some examples (for example, ones in which the pillars are non-removable from the thoracic portion) the pillars may be integrated into the thoracic portion so as to make the helmet portion and the thoracic portion a single structure. In these examples, the pillars may be integrated into the thoracic portion in a manner similar to their connection to the helmet portion, such as through an engineered network connecting the pillars within the thoracic portion (which may contain a rigid framework, as described above) to help better diffuse impact forces along the shoulders and/or to the chest.

In these examples, therefore, the helmet portion and the thoracic portion together comprise a single unitary engineered assembly which can be used by placing the thoracic portion over the head, and then lowering the assembly so that the helmet portion fits onto the wearer's head. However, in other examples, the pillars are connectable to and removable from the thoracic portion, and are not permanently integrated therein. In such cases a single unitary engineered assembly is created when the pillars are connected to the thoracic portion.

In some examples the thoracic portion may generally consist of or comprise a hard polymeric (e.g., a thermopolymer or carbon polymer) shell with foam and/or fluid filled padding underneath. The pads fit over the shoulders and the chest and rib area, and may be secured with various snaps and/or buckles, for example, at the front of the chest or near the bottom of the thoracic portion. Very preferably, although not invariably, the thoracic portion comprises a rigid inner framework.

In the present invention, the pillars are preferably integrated within, or joined to, the thoracic portion so as to distribute impact forces experienced by the helmet portion to the thoracic portion and thence throughout the thoracic portion by way of the rigid framework within the thoracic portion. In this way, the concussive force applied to the head is deflected from the head and brain to the shoulders and chest by a unitary engineered assembly or network.

In preferred examples, the helmet portion may be structured to be removable from the thoracic portion. For example, the pillars may comprise one or more quick-release mechanisms to permit the helmet portion to be removed quickly in the event of an injury. These quick-release mechanisms should be capable of activation both by the wearer or by another person (such as a medical technician or doctor), but should be structured in a manner that prevents unintentional activation of the quick-release mechanism during play or other activity, or malicious removal by an opposing player.

Examples of suitable quick-release mechanisms are well known to those of ordinary skill in the art, and may comprise any suitable quick release mechanism. Thus, such a quick release mechanism may comprise (without limitation) quick-release pins, which can be pulled to separate the pillars from the helmet portion or thoracic portion, gimbaled latch mechanisms similar to those disclosed in U.S. Patent Publication No. US 2014/0259319, loops and clasps, carabiners and the like. Thus, the quick release mechanism may comprise pillar connectors located at the downward end of each pillar.

Additionally or alternatively, certain of the examples of the present invention may include one or more quick-release mechanisms for the face mask of the helmet portion, permitting it to be removed or opened when the player is injured, or on the sidelines or bench, thus permitting the wearer to eat or drink, or for emergency medical aid to be provided when and as necessary without the need to remove the helmet. A particular example of a quick release mechanism for the face mask may comprise one or more hinges or pivot mounts that allow the face mask to be lifted up (similar to a face guard on a helmet for a suit of armor), or to the side.

In some examples, the present invention may be structured for the helmet portion to be placed on the head after the thoracic portion has been put on and fitted, in a manner similar to how the helmet of a deep sea diving suit is placed on the head and secured to the suit after the diver has put the remainder of the suit on. In such examples, the pillars of the helmet portion may terminate in a fixture that can then be firmly and strongly mated with or joined to a corresponding thoracic portion fixture (such as, without limitation, a force-diffusing component), preferably using quick-release fasteners.

In other examples, the helmet portion may comprise a plurality of pillars extending generally downward therefrom with pillar connectors at or near the lower portion of one or more pillars. Preferably, at least three pillars, or at least four pillars, have connectors located at or near their lowest point. Each connector may be structured to fit and lock to a corresponding connector receptacle located on or in the thoracic portion. Each connector of the helmet portion pillars may fit into, and lock within its corresponding receptacle. In such cases the connector receptacle is preferably an element of the rigid framework of the thoracic portion.

In one embodiment of the present invention, an impact diffusing system for protecting a head of a user of the system is provided. The system includes a headpiece cage having at least two support bars that extend from a top of the cage to a bottom of the cage, such that the support bars extend from an upper position above a top of the user's head to a lower position below a jaw line of the user. The support bars of the headpiece cage may be connected to each other at the top of the headpiece cage, above the top of the user's head. The headpiece cage may be structured to attach to a conventional helmet, such as to the outside surface of the conventional helmet. Alternatively, the impact diffusing system may further include an outer shell comprising a hard and durable material, such as a hard polymer, covering at least a portion of an outer surface of the headpiece cage and fixedly attached thereto.

In one example, the cage may include a first support bar along the coronal plane and a second support bar along the sagittal plane posterior to the head. The first support bar may extend from one side of the head adjacent to one shoulder, around the top of the head, to the other side of the head adjacent to the other shoulder. In another example, the cage may include two support bars, each of which extends from the upper position above the top of the user's head, along a plane that is between the coronal and sagittal planes, to the lower position that is near a respective trapezius area of the user posterior to the head.

The headpiece cage may further include a plurality of rigid bars that are sized and structured to surround at least a portion of a forehead, a top, and sides of the head, wherein the plurality of rigid bars are coupled to the support bars. Still further, the headpiece cage preferably includes a face mask structured to enclose at least a front portion of a face of the user. The face mask is coupled to at least one of the support bars. The face mask may protrude anterior to the coronal plane and may include a post extending from the face mask downward from a central area of the face mask. The face mask post may extend from a center of the face mask along the sagittal plane. Alternatively, the face mask post may extend from a position to one side of a center of the face mask, and the face mask may further include a second post that extends downward from the face mask at a second position to the other side of the center of the face mask. In still other examples, the face mask may entirely lack a post or pillar extending downward therefrom to an connection point on the thoracic portion.

The impact diffusing system further includes a thoracic framework structured to cover at least a portion of a chest, upper back, and shoulders of the user, wherein the thoracic framework is attached to, or capable of being attached to, the at least two support bars of the headpiece cage in a manner that prevents movement of the headpiece cage relative to the thoracic framework. The thoracic framework may also be attached to the post extending downward from the face mask. The system may further include inner thoracic padding and an outer thoracic shell, and the thoracic framework may be disposed between the inner thoracic padding and the outer thoracic shell. Alternatively, the thoracic framework may be structured to attach to conventional shoulder pads. The thoracic framework may include structurally reinforcing bars forming polygonal shapes that surround the at least a portion of the chest, upper back, and shoulders of the user. The thoracic framework may be formed of a rigid, inflexible material, such as titanium, steel, or another metal or metal alloy, carbon fiber, or a suitably strong polymer.

In one aspect of the invention, the thoracic framework may include rigid portions and flexible portions. The flexible portions may be formed by hinges, reduced thickness portions, or slots or openings formed within selected regions of the framework.

The thoracic framework may be permanently attached to the headpiece cage. For example, the thoracic framework and the headpiece cage may be manufactured as a unitary piece. The headpiece cage and the thoracic framework may comprise, without limitation, stainless steel, titanium and/or carbon fiber.

Alternatively, the thoracic framework may be removably attached to the headpiece cage. In this embodiment, the thoracic framework may include at least three connector receptacles and the headpiece cage may include at least three connectors each configured to removably attach to a respective one of the thoracic framework connector receptacles. The support bars of the headpiece cage may include a first support bar that extends along the coronal plane from one side of the head adjacent to one shoulder, around the top of the head, to the other side of the head adjacent to the other shoulder, and a second support bar partially along the sagittal plane posterior to the head. A first connector may be disposed at a first end of the first support bar, a second connector may be disposed at a second end of the first support bar, and a third connector may be disposed at an end of the second support bar.

In another aspect, the cage may include two support bars, each of which extends from the upper position above the top of the user's head, along a plane that is between the coronal and sagittal planes, to the lower position that is near a respective trapezius area of the user posterior to the head. In this aspect, the headpiece cage may include three connectors, wherein one of the three connectors is at an end of a post extending from the face mask, and the other two connectors are at respective lower ends of the two support bars. Thus, the impact diffusing system of this embodiment may include at least three connection points between the thoracic framework and the headpiece cage. The term “connection point” as used herein refers to a location at which the headpiece cage and the thoracic framework are joined together in a manner that limits or prevents movement of the headpiece cage relative to the thoracic framework.

In yet another aspect, the headpiece cage may include four connectors, wherein none of the four connectors is at an end of a post extending from the face mask. In this aspect, a first support bar may extend along the coronal plane from one side of the head adjacent to one shoulder, around the top of the head, to the other side of the head adjacent to the other shoulder, with a connector at each end of this support bar. The headpiece cage may comprise a second support bar along the sagittal plane posterior to the head, connecting to the first support bar at a position approximately at the crown of the head. A third support bar may extend laterally around the back of the head and connecting at each end to the first support bar at a position approximately below the ears of the wearer, and at its midpoint to the lower end of the second support bar. Two posterior pillars are connected to the third support bar at a position to the right and to the left, respectively, of the medial plan of the wearer's head when the invention is in use. The posterior pillars extend from the third support bar in a direction simultaneously downward, laterally and posteriorly to connection points on the rear shoulders of the thoracic portion. Connectors may be disposed at each end of the first support bar and at the end of each of the two posterior pillars, and connector receptacles are disposed at appropriate connection points on the thoracic portion. In other embodiments, the headpiece cage and the thoracic portion may be made as a single unit, wherein the headpiece portion is not detachable from the thoracic portion.

The impact diffusing system may include inner headgear structured and sized to conform to the user's head and to fit inside the headpiece cage. The inner headgear may be sized and structured to be moveable relative to the headpiece cage. The inner headgear may include a friction-reducing outer coating that reduces friction when the inner headgear moves relative to the headpiece cage. Similarly, the headpiece cage may include a friction-reducing inner coating that reduces friction when the inner headgear moves relative to the headpiece cage. The inner headgear may include impact absorbing padding. The padding may be inflatable padding and/or smart material padding. Preferably the outer surface of the inner headgear does not contain any retaining stop, protrusion, projection, item of padding or other feature that is structured or effective to interact with a retaining stop, protrusion, projection, item of padding or other feature on the inside surface of the helmet portion worn by the wearer of the inner headgear to substantially restrict movement of the wearer's head within the helmet component during use.

In preferred embodiments a shell comprising an impact resistant material, such as, without limitation, a thermopolymer or carbon polymer may be firmly attached to the headpiece cage so as to cover at least the posterior portion of the wearer's head and a portion of the neck during use. Very preferably, preferably the shell is structured to provide ventilation to the head—particularly to the back of the head and/or neck between the collar of the thoracic portion and the lower margin of the helmet outer shell. For example, the shell may comprise a plurality of voids or vents defined in the back and/or sides thereof, preferably penetrating through the inner surface of the shell portion and any padding comprised on the inner surface of the headpiece cage. These voids or vents permit fresh air to cool the head and also provide sweat and water vapor to escape entrapment on the inner surface of the headpiece cage. Also, when the headpiece cage and thoracic portion are joined, a gap may preferably be defined between the lower margins of the shell and the collar of the thoracic portion, exposing the back of the upper neck to fresh air. In one embodiment the shell may be affixed to the headpiece portion with a lower margin thereof extending approximately along the axis defined by the third support bar; laterally around the back of the head. This arrangement permits heat and sweat to escape from the head under the posterior sections of the shell.

Another embodiment of the present invention is directed to an impact diffusing system for protecting a head of a user of the system, wherein the system includes a helmet component comprising a solid, rigid unitary piece structured to surround a top, a back, and sides of the user's head, such that ears of the user and at least a portion of a neck of the user are enclosed within the helmet component. The system further includes a rigid thoracic cage structured to cover at least a portion of a chest, upper back, and shoulders of the user, wherein the thoracic cage is attached to the helmet component in a manner that prevents movement of the helmet component relative to the thoracic cage. The thoracic cage may be attached to the helmet component via at least four connection points, which may include two front connection points that are anterior to a coronal plane, and two rear connection points that are posterior to the coronal plane. Embodiments having at least three connection points may include a connection point located at the front or the back of the user's body and positioned substantially on the sagittal plane, and two side connection points located on the sides of the user's body above the shoulders and near (or slightly anterior to or posterior to) the coronal plane. The connection points may be permanent connectors and the thoracic cage may be fixedly attached to the helmet component. Alternatively, the connection points may comprise quick-release connectors and the thoracic cage may be removably attached to the helmet component.

The thoracic cage and the helmet component may be made of substantially inflexible material. For example, the thoracic cage and the helmet component may be made of carbon fiber.

The system of this embodiment may also include inner headgear structured and sized to conform to the user's head, fit within the helmet component, move with the user's head, and move relative to the helmet component.

The system of this embodiment may also include inner thoracic padding and an outer thoracic shell, and the thoracic cage may be disposed between the inner thoracic padding and the outer thoracic shell. Alternatively, the thoracic cage may be structured to attach to conventional shoulder pads.

In accordance with another embodiment, the present invention is directed to an impact diffusing system for protecting a head of a user of the system, wherein the system includes a rigid thoracic framework structured to cover at least a portion of a chest, upper back, and shoulders of the user. The system further includes a headpiece cage structured to surround a top, sides, and back of the head. The cage includes at least two support bars extending from a top of the cage to a bottom of the cage, wherein top ends of the support bars are attached to each other, and bottom ends of the support bars are attached to the rigid thoracic framework in a manner that prevents movement of the headpiece cage relative to the thoracic framework. The cage further includes a plurality of rigid bars that are sized and structured to surround at least a portion of a forehead, a top, and sides of the head, wherein the plurality of rigid bars are coupled to the at least two support bars. Still further, the cage includes a face mask structured to enclose at least a portion of a face of the user, wherein the face mask is coupled to at least one of the support bars. The face mask may protrude anterior to a coronal plane and comprise a post extending downward from a bottom of the face mask from a central area of the face mask, such that the post is positioned anterior to a throat of the user. The post may be attached to the rigid thoracic framework, such that the headpiece cage and the thoracic framework are attached to each other at least at three attachment points. In other embodiments, the face mask may lack a post extending downward from a bottom portion thereof to the thoracic framework.

DETAILED DESCRIPTION

Disclosed herein is an impact diffusing system for protecting the head of a user of the system. Conventional helmets distribute impact forces throughout the helmet. With the system of the present invention, impact force is more evenly distributed throughout the system instead of being concentrated at the point of impact or distributed throughout just the helmet.

In one example, as shown inFIGS. 1A-1D, the system100includes a helmet portion102coupled to a thoracic portion104. The helmet portion102surrounds, or encloses, the head of the user, and the thoracic portion104encloses a portion of the thoracic region of the user. The thoracic region is the part of the body that lies between the neck and the abdomen, and includes the breastbone, heart, lungs, ribs, thoracic vertebrae, chest, and shoulder girdle (i.e., the clavicle and scapula). In the embodiment shown inFIGS. 1A-1D, the thoracic portion104of the system100includes a chest portion110for covering part of the chest of the user, including the sternum and at least a portion of the pectoral area. The thoracic portion104further includes a shoulder portion112that surrounds a front, top, and back of the shoulders of the user, including the upper tip of the humerus, the shoulder girdle, and the front upper shoulders. A back portion114of the thoracic portion104covers a portion of the upper back of the user, including the rhomboid muscles and an upper part of the trapezius muscles.

The helmet portion102of the system100is attached to the thoracic portion104such that the helmet portion102is stationary and fixed relative to the thoracic portion104. Lateral, posterior, and anterior movement of the helmet portion102relative to the thoracic portion104is at least limited, if not eliminated. In this manner, rather than resting on the user's head, like a conventional helmet, the helmet portion102of the system100rests upon the thoracic portion104so that all, or substantially all, of the weight of the system100is applied to the user's thoracic region. There is space between the inner surface of the helmet portion102and the user's head so that the user's head may move relative to the helmet potion102. The user's head may rotate side to side as well as up and down within the helmet portion102. Preferably, the user's head is able to turn up to about 90 degrees to the left and to the right, relative to center. Preferably, the user's head is able to bend towards the chest up to about 60 degrees relative to neutral head position, and to tilt back up to about 70 degrees relative to neutral head position.

The helmet portion102of this example comprises a resilient shell103substantially surrounding the back and sides of the wearer's head. The outer shell103provides hard, resilient outer protection and shock absorption and may be made of a durable polymer, such as polycarbonate. The inner framework of the helmet portion102includes main support bars122and124, and the outer shell103is fixedly attached (e.g., by screws, bolts, a strong adhesive, or other such fasteners) to the outside surfaces of the main support bars122,124. Thus, the force of impacts to the outer shell103is deflected to support bars122,124. In some examples, the user's field of view may be partially obstructed above and below the eyes by rigid bars of the face mask portion of the helmet portion102, but not by the outer shell103. That is, the outer shell103is disposed outside of the user's peripheral vision when the user is looking straight ahead. The outer shell103surrounds a face opening that is wider, and optionally higher, than that of a conventional football helmet. In some, currently less preferred examples, at least a portion of the outer surface of the helmet portion102may comprise a soft padding overlying a hard shell, as described above.

In yet another example, rather than having a hard shell applied to the outer surface of the helmet portion102, the framework of the helmet portion102may be sized and structured to be attached to a conventional helmet. For example, as shown inFIGS. 2A and 2B, the framework of the helmet portion102is sized and structured to attach to the outside of a conventional football helmet that has been modified to fit within the system100. In the example shown inFIGS. 2A and 2Bthe main support bars122′,124′ are coupled to the outside of a conventional football helmet shell103′. A face mask107′ and a plurality of rigid bars105′ surround the user's face and are attached to the main support bars122′,124′ and to the helmet shell103′.

Referring back toFIGS. 1A-1D, the front of the helmet portion102may comprise, for example, a “birdcage-style” face mask107covering a portion of the face opening. The face mask107is structured and designed in a manner similar to standard football face masks (except preferably larger), or face masks containing any suitable number of bars in any other shape sufficient to provide protection to the wearer's face. The face mask107encloses at least the lower portion of the face of the user, and protrudes anterior to the front of the user's face. The bars of the face mask107may be comprised of any sufficiently rigid material, such as metal and/or hard plastic. For example, the bars of the face mask107may be made of plastic- and/or elastomer-covered metal, stainless steel, titanium, carbon fiber, or any combination thereof. The face mask107is strongly affixed to the support bars122,124. In an alternate embodiment, the face mask107may be joined to the support bars122,124with one or more hinges or pivot mounts, such that the face mask107may be lifted upwards, similar to a face guard on a suit of armor helmet, or opened sideways, like a birdcage door, upon the disconnection of a strong latch preventing unintentional opening of the face mask107. Other face masks, such as transparent face masks, may be used in other examples of the present invention, such as in racing or military applications, in which routine risk of blows directly to the face are not as common as in football. The face mask107prevents the user's face from sustaining a direct blow. Rather, the force of an impact sustained by the face mask107will be transferred to the support bars122,124and to the thoracic portion104of the system100.

As shown in e.g.,FIG. 1B, face mask107includes a face mask pillar140that extends downward from the bottom of the face mask107and terminates in a connector142for connecting the pillar140to the thoracic portion104. The connector142at the bottom of the face mask pillar140is positioned such that the connection between the pillar140and the thoracic portion104will be near the user's sternum. The face mask pillar140is in about the center of the face mask107and is positioned anterior to the user's throat.

In alternate embodiments, the face mask107may include more than one face mask pillar. For example, the embodiment shown inFIG. 3is similar to that shown inFIGS. 1A-1D, except that the face mask107includes two face mask pillars140′. Each of the face mask pillars140′ extends downward from the bottom of the face mask107and is positioned in the central area on either side of the center of the face mask107, anterior to the user's throat. Those of ordinary skill in the art will recognize that the face mask107may include any suitable number and configuration of face mask pillars140extending downwardly from the bottom of the face mask107. Those of ordinary skill in the art will also recognize that the face mask107may not include a face mask pillar at all, as discussed in more detail below with reference toFIGS. 6A and 6B.

Referring back toFIGS. 1A-1D, the helmet portion102of the system100surrounds most of the head, with the exception of a front window (in this case rectangular in shape)109that provides the user with a visual field. The front window109does not include any bars. The front window109may be similar to that of a conventional helmet. However, the size (particularly, but not necessarily exclusively, the width) of the face mask107, and the corresponding front window109of the helmet portion102are each preferably larger and/or wider than traditional football helmets, since the wearer's head is preferably not restricted from moving substantially within the interior of the helmet portion102. The helmet portion102may optionally include a visor (not shown) for covering the window109and protecting the eyes of the user.

The helmet portion102further includes a plurality of rigid bars105near the user's forehead. These bars105form a cage-like structure for protecting the front of the user's head, including the forehead, the forward portion of the top of the head, and the upper portion of the sides of the head. The plurality of rigid bars105surrounding the forehead are attached to the support bars122,124in order to deflect the force of impacts near the front of the head to the support bars122,124and to maintain the structural integrity of the helmet portion102. In this manner, the plurality of bars105prevents the forehead from sustaining a direct blow.

Referring now toFIGS. 4A-4D, the system100is depicted with the outer shell103removed in order to more clearly show the headpiece cage in the helmet portion102. The cage of the helmet portion102includes the two support bars122,124surrounding the back and sides of the user's head, the plurality of rigid bars105enclosing the forehead, top and sides of the user's head, and the face mask107for protecting the face of the user130. The support bars122,124are rigid and function as the main struts and as major structural elements of the helmet portion102. The support bars122,124are wider than the other bars105,107of the helmet portion102. Most of the force of an impact to the helmet portion102will be transferred to the support bars122,124, which will then transfer the force of the blow to the thoracic portion104of the system100, thereby avoiding injury or unattenuated impact to the user's head.

As shown inFIGS. 4A-4D, the two support bars122,124include a first support bar122along the coronal plane132and a second support bar124along the sagittal plane134. The coronal plane132is a vertical plane that is perpendicular to the ground and that divides the human body into ventral and dorsal (or belly and back) sides (seeFIG. 4B). The sagittal plane134is a vertical plane that is perpendicular to the ground and to the coronal plane132and that divides the human body evenly into left and right sides (shown inFIGS. 4A and 4D). The first support bar122has an arch shape, or an inverted “U” shape. The ends of the first support bar122form pillars140that protrude from the bottom of the helmet portion102to a lower position below the jaw line of the user. The pillars140are coupled to the thoracic portion104in a location adjacent to the tops of the user's shoulders. For example, these side connection points between the helmet portion102and the thoracic portion104are near the upper tip of the humerus of the user, and are on the same horizontal plane as each other. The first support bar122curves over the top of the user's head, with the top of the first support bar122being positioned above the top of the user's head.

The second support bar124is shaped like half of an arch or half of an inverted “U.” The bottom end of the second support bar124forms a rear pillar140that protrudes from the bottom of the helmet portion102and that connects to the thoracic portion104near the upper back or bottom neck region of the user130. For example, this rear connection point between the helmet portion102and the thoracic portion104is near the vertebrae of the user130at approximately the bottom of the cervical vertebrae or the top of the thoracic vertebrae. Thus, the rear connection point is elevated relative to the front connection point between the face mask107and the thoracic portion104, as can be seen clearly inFIGS. 1B and 4B. The connection points between the helmet portion102and the thoracic portion104are positioned below the user's line of sight, and preferably below the jaw line of the user. The support bars122,124are coupled to each other above the top of the user's head in order to reinforce each other and more evenly distribute impact forces.

The plurality of pillars140are integrated as part of the helmet portion102itself. For example, the pillars140are formed as an integral part of the helmet portion102. The headpiece cage, including the bars105, the face mask107, the support bars122,124, and the pillars140, comprises a suitably strong and lightweight material, such as, without limitation, one or more of titanium, a titanium alloy, a non-titanium metal, a nanostructured ceramic, a nanostructured metal or metal alloy, a thermopolymer, or a carbon polymer. In the present invention, the pillars140are preferably anchored below neck level to the chest, shoulders and upper back (over the scapulae). By attaching the pillars140in this location, a sliding horizontal blow is concentrated on the upper body rather than the neck, and the force is distributed over a larger surface than the neck and collarbone.

In an alternate embodiment, shown inFIGS. 5A and 5B, the system100″ is substantially similar to the system100shown inFIGS. 1A-1DandFIGS. 4A-4D, except that the support bars122″,124″ in the helmet portion102″ are disposed between the coronal and sagittal planes132,134. That is, the support bars122″,124″ extend from a position above the top of the user's head and terminate at a lower position that is posterior to the head and near the trapezius muscle or the scapula of the user130. As shown inFIG. 5B, the outer shell103″ (shown in phantom) of the helmet portion102″ extends posterior to the support bars122″,124″. In this embodiment, the helmet portion102″ includes only three pillars140″ that are coupled to the thoracic portion104″ of the system100″. One of the pillars140″ protrudes from the bottom of the face mask107″, and the other two pillars140″ are at the ends of the support bars122″,124″.

In another alternate embodiment, shown inFIGS. 6A and 6B, the system300is substantially similar to the system100shown inFIGS. 1A-1DandFIGS. 4A-4D, except that the face mask pillar is removed. Thus, the helmet portion302is coupled to the thoracic portion304through pillars340at the ends of the support bars322,324. That is, there are only three connection points between the helmet portion302and the thoracic portion304. However, the embodiments shown inFIGS. 1A-6Bare not intended to limit the scope of the invention, and one of ordinary skill in the art will recognize that there may be any number of pillars and support bars that may be arranged in many different configurations in order to couple the helmet portion to the thoracic portion in a manner that prevents movement of the helmet portion relative to the thoracic portion.

Referring back to the system100inFIGS. 1A-1DandFIGS. 4A-4D, the helmet portion102is coupled to the thoracic portion104in a manner that restricts or eliminates lateral, anterior, and posterior movement of the helmet portion102relative to the thoracic portion104. As discussed above, the helmet portion102of the example shown inFIGS. 1A-1D and 4A-4Dhas four pillars140joining the helmet portion102to the thoracic portion104and extending substantially downward from the helmet portion102. In particular, the helmet portion102of this example includes one pillar extending from the bottom of the central area of the face mask107, one pillar positioned behind the user's head, and one pillar positioned adjacent to the tops of each of the user's shoulders. In other examples, as discussed above, the number of pillars may vary. The pillars140are preferably strong and may be substantially inflexible. By “substantially inflexible” or “substantially rigid” is meant that elements of the system are strong and resilient enough to withstand the forces expected to be encountered in the sport or activity during which the system is used without breaking or flexing more than about 0.25 inches, or about 0.5 inches or about 1 inch. The pillars140are connected within the helmet portion102in such a manner so as to distribute the force of a blow to any portion of the helmet portion102among the plurality of pillars140. The lower portion of each of the pillars140preferably comprises a connector component142structured to join securely and firmly within a corresponding connector receptacle of the thoracic portion104. The connector receptacle of the thoracic portion104is attached to, or integrated as part of, the framework of the thoracic portion104. Alternatively, the connector receptacle may be part of the helmet component102, and the connector component142may be part of the thoracic portion104. Very preferably, the connector component142and the connector receptacle of the thoracic portion104are structured to be rapidly releasable, thereby permitting the helmet portion102to be quickly detached from the thoracic portion104and removed by the player or by a doctor, coach, or medical technician, if desired. This may be advantageous in the event of an injury to the user of the system100.

Although those of ordinary skill in the art will recognize that any type of connector may be used to couple the helmet portion102to the thoracic portion104, an exemplary “pin-type” quick release mechanism is depicted inFIGS. 7A and 7B. In this example, the connectors142include an annular finger grip152and a central push button154. When the annular finger grip152is grasped with the fingers and the push button154is depressed with the thumb of the same hand, the connector142disengages from the connector receptacle on the thoracic portion104. When the push button154is released, the connector142engages. As such, using such a connector142, the helmet portion102and the thoracic portion104can quickly be separated by depressing the push button154relative to the finger grip152and pulling the connector142away from the connector receptacle, so that it disengages from the connector receptacle of the thoracic portion104of the system100.

Referring back toFIGS. 1A-1D and 4A-4D, the thoracic portion104comprises inner padding176and an outer shell178. The outer shell178is formed of a hard plastic and provides impact resistance and protection to the user. The outer shell178may include shoulder plates, arm plates and body plates. The polymeric outer shell178overlies the inner padding176, which may be a polymeric foam. The inner padding176may in other examples be a fluid-filled padding. The thoracic portion104is shown with a belt or cinch to secure the thoracic portion104around the thoracic region of the user. A rigid framework is disposed between the inner padding176and the outer shell178. In this manner, the inner padding176is in direct contact with the user's thoracic region and provides cushioning between the user and the framework so that the thoracic portion104is comfortable to wear. As shown inFIGS. 8A and 8B, the rigid framework170comprises a plurality of substantially rigid bars172. The bars172may be comprised of a rigid, substantially inflexible material, such as metal or hard plastic. For example, the bars172may be stainless steel, titanium, carbon fiber, or any combination thereof. The rigid bars172of the thoracic portion104are substantially vertical or substantially horizontal, and may form polygonal shapes, thus distributing forces like a geodesic dome, in which triangular elements of the dome are structurally rigid and distribute structural stress throughout the structure.

With reference toFIGS. 8A and 8B, the pillars140extending from the bottom of the helmet portion102are attached to the bars172of the framework170. In particular, the pillars140are coupled to substantially horizontal portions of the framework170. In this manner, impact forces sustained by the helmet portion102are transferred to the rigid framework170of the thoracic portion104, thereby protecting the head of the user. In other words, the framework170receives force from a blow or shock to the helmet portion102through the pillars140and distributes the force of the blow or shock through the framework170of the thoracic portion104, thus lessening the severity of this force at any one point, and distributing the force through the shoulders, chest, and musculature of the back.

In an alternative embodiment, the framework170may be structured to be attached to a conventional shoulder pad apparatus, such as the shoulder pads worn by football players. As shown, the framework170is arranged along the chest, back and along the shoulders so as to diffuse the force of a blow to the helmet portion102transmitted through the pillars140and then throughout the thoracic portion104to the shoulders and upper body and away from the head. The framework170is rigid enough to absorb and direct a force received from the helmet portion102to the shoulders and back in preference to the neck or spine.

The thoracic framework170may preferably be fabricated as part of the thoracic portion104, with connector receptacle components built therein. Less preferably, but still within the scope of this invention, the framework170may be fabricated as a separate element to be secured to an existing shoulder pad, for example, with nylon webbing and buckles, or another similar suitably strong connector. In either case, the thoracic portion104very preferably comprises a rigid framework170that distributes the force of the transmitted blow through the shoulders, chest, and musculature of the back.

In one embodiment (not shown), the rigid framework170includes rigid portions and flexible portions. Flexibility in certain areas of the framework170may be necessary in order to facilitate the range of motion required by the user, depending on the user's activities or player position. Such flexible portions in the framework170may be formed by hinges, reduced thickness portions, or slots or openings formed within selected regions of the framework170.

In an alternative embodiment, the thoracic framework170and the headpiece cage are manufactured as a single, unitary piece. In such an embodiment, the helmet portion and the thoracic portion cannot be disconnected, and the connectors are eliminated.

The system100further includes inner headgear190that is attached to, and in direct contact with, the head of the user130, as depicted inFIGS. 4A-4D. The inner headgear190surrounds the back, sides, and top of the user's head, as well as the user's forehead. The inner headgear190is fixed relative to the user's head, and thus moves with the user's head and moves relative to the helmet portion102of the system100. The inner headgear190may be comprised of polymeric material and is preferably lightweight. The inner headgear190includes padding for protecting the user's head from the force of a collision with the inner surfaces of the helmet portion102. Any padded headgear that can be fixed to the user's head may be used with the system100, and is not limited to the one-piece padded headgear190shown inFIGS. 4A-4D.

In one embodiment, shown inFIGS. 9A-9E, the inner headgear290includes padding that underlies a skin comprising a smooth, low friction material such as a TEFLON® lubricant surface. The padding includes wedge-shaped pads291at the top of the user's head, a forehead pad292, side pads293surrounding each one of the sides the user's head (including the ears), and a rear pad294(seeFIGS. 9D and 9E) at the back of the user's head between the side pads293. Each of the pads291-294may be made of impact absorbing padding, such as inflatable padding, fluid-filled padding, foam padding, smart material padding (e.g., PORON® XRD®, D30®, or the like), or any combination thereof. Smart material padding is formed of an elastic polymer that stiffens upon impact. The inner headgear290also includes a chin strap295for securing the headgear290to the user's head. Each of the pads291-294is connected to the other pads291-294through a layer of material296. In this manner, the pads291-294are able to move and flex relative to each other. The inner headgear290and the helmet portion102are constructed so that there is a space between the outer surface298of the inner headgear290and the inner surface of the helmet portion102so that the user's head may turn side to side, as well at tilt forward and back, relative to the helmet portion102without interference or friction from the helmet portion102. The outer surface of the inner headgear290may be untextured and substantially smooth.

Alternatively or additionally, the outer surface298of the inner headgear290and the inner surface of the helmet portion102may be coated with a friction-reducing material, such as polytetrafluoroethylene, in order to facilitate movement of the inner headgear290relative to the helmet portion102. Alternatively or additionally, the helmet portion102may include inner padding attached thereto, including a floating top plate that is rotatable relative to the outer shell103of the helmet portion102, such as those disclosed in FIGS. 4-6 of U.S. Pat. No. 9,462,841, which is hereby incorporated herein by reference in its entirety. The inner padding of the helmet portion102may be in contact with, or spaced apart slightly from, the inner headgear290.

In this manner, during use, the wearer will have the benefit of the protection of the protective headpiece cage, while the inner headgear190,290and the space within the helmet portion102will allow the wearer to move the head relatively freely within the helmet portion102in order to be able to scan the playing field and/or outside environment without requiring the shoulders or body to move.

In another embodiment, shown inFIGS. 10A and 10B, an impact diffusing system200includes a helmet portion202and a thoracic portion204, both of which are formed of a rigid, lightweight material, such as carbon fiber. The helmet portion202comprises a unitary shell206that surrounds the back, sides, and top of the user's head. The helmet portion202further includes pillars208that protrude from the bottom of the helmet portion202and that include connectors210for connecting the helmet portion202to the thoracic portion204. The pillars208in this embodiment are wider than the pillars140in the previous embodiments. The shell206and the pillars208may be formed separately and then affixed to each other, or the shell206and the pillars208may be fabricated as a continuous, unitary piece. The thoracic portion204includes thoracic framework212that fits over and around the user's shoulders, back and chest. The thoracic framework212includes connector receptacles for coupling to the connectors210on the helmet portion202. In the embodiment shown inFIGS. 10A and 10B, there are four connectors210that connect the helmet portion202to the thoracic portion204. Two of the connectors210are anterior to the coronal plane132and positioned at the front of the user's body. The other two connectors210are posterior to the coronal plane132and positioned at the back of the user's body. However, those of ordinary skill in the art will recognize that the system200may include more than four connectors or fewer than four connectors and that the connectors may be positioned anywhere between the helmet portion202and the thoracic portion204. The connectors210are below eye level, and are preferably below the jaw line of the user. Similar to the above embodiments, the connectors210are preferably quick-release connectors. Alternatively, the thoracic framework212, the helmet shell206, and the helmet pillars208may be manufactured as a single, unitary piece, thereby eliminating the connectors and connector receptacles. Similar to the above embodiments, the thoracic framework212is disposed between inner padding and an outer shell (not shown). Alternatively, the thoracic framework212may be sized and structured to be attached to a conventional shoulder pad apparatus, such as the shoulder pads worn by football players. Also similar to the above embodiments, the system200includes inner headgear that is affixed to the user's head and configured to move relative to the helmet portion202. For example, the inner headgear190depicted inFIGS. 4A-4D, or the inner headgear290depicted inFIGS. 9A-9Emay be used in the system200. The system200may further include a face mask, similar to the face mask107in the above embodiments. The face mask for the system200may be attached to the helmet shell206and/or the pillars208with a hinge or pivot mount such that the face mask may be opened to provide access to the user's face during use. Alternatively, such a face mask may be permanently attached to the shell206and/or the pillars208. The system200may further include a visor or other eye protection (not shown).

InFIGS. 11A-11D, another embodiment of an impact diffusing system400is depicted. This system400is similar to the system200shown inFIGS. 10A and 10B, except that the pillars408,409in the system400are in a different configuration than the pillars208in the system200. The system400comprises a helmet portion402, a thoracic portion404, and three pillars that extend between, and are coupled to, the helmet portion402and the thoracic portion404. In particular, the system400comprises two front pillars408that are anterior to the coronal plane132and a wide rear pillar409that is posterior to the coronal plane132. The front pillars408each include one connection point410. The rear pillar409includes four connection points410. The system400is depicted including a face mask407and a plurality of rigid bars405for surrounding the user's forehead area, and one of ordinary skill in the art would recognize that a face mask and plurality of rigid bars may similarly be incorporated into the system200depicted inFIGS. 10A and 10B. One of ordinary skill in the art would also recognize that any number and configuration of pillars and connectors may be used to couple the helmet portion to the thoracic portion in a manner that prevents movement of the helmet portion relative to the thoracic portion.

Another embodiment of an impact diffusing system500is depicted inFIGS. 12A-12D. This system500is similar to the systems200and400inFIGS. 10A and 10B and 11A-11D, respectively, but the system500depicts another alternative for the configuration of the pillars, and the face mask is larger than other embodiments. The impact diffusing system500includes a helmet portion502, a thoracic portion504, and pillars506,508that extend between, and are coupled to, the helmet portion502and the thoracic portion504. The helmet portion502of the system500includes a hard exterior shell512in the back of the helmet portion502, a face mask507, and a plurality of rigid bars505for surrounding the user's forehead area. The face mask507and rigid bars505are attached to the hard shell512using a conventional attachment mechanism, such as screws, nuts and bolts, or the like. The face mask507is larger than in previous embodiments. The enlarged face mask507may improve the visibility of the user130. In other words, the face mask507is large enough that the hard shell512on the back of the helmet portion502does not obscure the user's view when the user130turns their head relative to the helmet portion502. The hard exterior shell512may be made of a rigid, lightweight, impact-resistant material, such as hard plastic, polymer, polycarbonate, carbon fiber, or the like. Similar to previous embodiments, the face mask507and rigid bars505may be made of metal, polymer-coated metal (e.g., powder-coated titanium, or the like), hard plastic, or another sufficiently rigid material that is able to withstand several impacts.

The connecting pillars include two front pillars506that are anterior to the coronal plane132(shown inFIG. 4B) and have a connection point near the front of the shoulder of the user130. The two front pillars506may be formed of metal, polymer-coated metal (e.g., powder-coated titanium, or the like), or another sufficiently rigid material. The connecting pillars further include two rear pillars508that are posterior to the coronal plane132and connect to the thoracic portion504in an area near the upper back and rear shoulder of the user130. The rear pillars508may be formed of metal, or a rigid, lightweight material, such as plastic, carbon fiber, or the like. The rear pillars508and the exterior shell512of the helmet portion502may be manufactured as a unitary piece, and thus formed of the same material. Alternatively, the rear pillars508may be made separately and then attached to the hard exterior shell512of the helmet portion502. The pillars506,508are disposed between the coronal plane132and sagittal plane134(shown inFIGS. 4A and 4D). The pillars506,508, face mask507, and rigid bars505may all be made of the same material, or may all be made of different materials. Similar to the above-disclosed embodiments, the pillars506,508, face mask507, and rigid bars505comprise a suitably strong and lightweight material, such as, without limitation, one or more of titanium, a titanium alloy, a non-titanium metal, a nanostructured ceramic, a nanostructured metal or metal alloy, a thermopolymer, or a carbon polymer.

The pillars506,508may connect to the thoracic portion504using any type of connection mechanism. The connection mechanism is preferably a quick-release mechanism so that the helmet portion502can be quickly released and removed from the thoracic portion504in case of emergency. In this embodiment, as depicted more clearly inFIGS. 13A and 13B, the connection mechanism includes a cotter pin542that passes through a hole in a pin544that protrudes through the pillars506,508. A damper546is disposed between the pillars506,508and the thoracic portion504in order to absorb some of the impact that may be sustained by the system500. The upper surface of the damper546is in direct contact with the lower surface of the pillar506, and the lower surface of the damper546is in direct contact with the hard outer shell514of the thoracic portion504. Such a damper may also be disposed between the face mask and the hard outer shell of the helmet portion of any of the embodiments described herein. The pin544is permanently coupled to the hard outer shell514of the thoracic portion504and extends through a hole in the damper546and a hole in the lower surface of the pillar506. The damper546may be made of rubber, foam, or other such impact-absorbing materials.

Similar to the above embodiments, the system500further includes inner headgear590(shown inFIGS. 12A and 12B) that is attached directly to the head of the user130, and is configured to move relative to the helmet portion502. The inner headgear590may be substantially similar to the inner headgear190depicted inFIGS. 4A-4D, or the inner headgear290depicted inFIGS. 9A-9E.

The thoracic portion504includes a hard outer shell514disposed over a padded vest516. The hard outer shell514may be made of a rigid, lightweight material that is capable of sustaining repeated impact without breaking, such as plastic, carbon fiber, or the like. The hard outer shell514may alternatively or additionally be made of metal, or other such suitably rigid materials. The padded vest516is in direct contact with the user130and is positioned between the user130and the hard outer shell514. In this manner, the padded vest516absorbs some of the force when an impact occurs, thereby preventing or reducing injury to the user130. The padded vest516, depicted in more detail inFIGS. 14A-14C, covers the upper torso of the user130, including the upper back, chest, and tops of the user's shoulders. The padded vest516may be permanently or removably attached to the hard outer shell514. For example, the padded vest516may include hook and loop fasteners550(e.g., Velcro®) for securing the vest516to the outer shell514in various discrete places around the vest516. Similar to previous embodiments, the padding in the vest516may include polymeric foam, memory foam, smart material padding, fluid, or the like. The thoracic portion504may alternatively include other styles of padding that are not in a vest configuration and that may be positioned between the user130and the hard outer shell514.

The thoracic portion504further includes side straps520(shown inFIGS. 12A-12C) for securing the thoracic portion504to the user130. Although two side straps520are depicted inFIGS. 12A-12C, the thoracic portion504may alternatively include only one side strap that goes all the way around the outer shell514. The side straps520may include nylon webbing and a buckle, similar to a seat belt. However, one of ordinary skill in the art will recognize that any other means of securing the thoracic portion504to the torso of the user130may be employed. The securing meaning is preferably adjustable and includes a mechanism for tightening or cinching down the thoracic portion504after it is positioned on the user130in order to secure the thoracic portion504to the user130in a manner that prevents or minimizes movement of the thoracic portion504relative to the thoracic region of the user's body.

As shown inFIG. 15, the system500may further include padding552along the lower bars of the face mask507and the front pillars506. This umpire mask-style padding552protects the user's chin. As shown inFIG. 16, the system500may further include a neck collar554for padding the user's neck and preventing drastic head movement when the system500sustains an impact.FIGS. 15 and 16further depict padding556on the interior surface of the helmet portion502. This interior padding556protects the user's head from impact with the hard outer shell512. One of ordinary skill in the art would readily recognize that the padding552,554,556depicted inFIGS. 15 and 16may also be employed in the other embodiments depicted herein.

The face mask in any of the above embodiments may be configured to rotate up relative to the outer shell of the helmet portion. For example, as shown inFIGS. 17A and 17B, the face mask607is rotatably attached to the hard outer shell612of the helmet portion602of the system600. This system is similar to those shown inFIGS. 12A-16, but it will be readily understood by one of ordinary skill in the art that a rotatable face mask could be incorporated into any of the embodiments disclosed herein. The face mask607is attached to the hard outer shell612at rotatable attachment points614on the sides of the shell612and a releasable attachment616at the top of the shell612. The face mask607is attached to the thoracic portion604of the system600through connecting pillars606and attachment mechanism608. The connectors608,616on the thoracic portion and top of the hard outer shell612may be released, allowing the face mask607to swivel upwards relative to the shell612, as shown inFIG. 17B. The face mask607rotates about the attachment points614. The embodiment shown inFIGS. 17A and 17Bfurther includes a visor620for shielding the user's eyes and upper face. The visor620may be polycarbonate or another similar light-weight, durable material. The visor620is transparent and may be clear or tinted.

In yet another embodiment, shown inFIGS. 18A and 18B, rather than being a single piece, the face mask707is a two-part face mask having an upper portion705and a lower portion703. The lower portion703of the face mask707is attached to the hard outer shell712on the sides of the hard outer shell712. The upper portion705of the face mask is attached to the upper portion of the hard outer shell712. The upper portion705and lower portion703of the face mask707are not attached to each other, and thus are able to move independently of each other. For example, one or both of the lower portion703and the upper portion705may be rotatable relative to the hard outer shell712of the helmet portion702. In another example of a two-piece face mask, shown inFIG. 18B, the lower portion703of the face mask707is connected to the pillars708rather than to the sides of the hard outer shell712. In this manner, the lower portion703covers the gap between the pillars708. While the two-part face mask707is depicted as being connected to a helmet portion similar to those inFIGS. 10A-11D, it will be readily understood by one of ordinary skill in the art that any of the embodiments disclosed herein may be made with a two-piece face mask. It will further be understood that the lower portion703of the face mask707may have one or more pillars attached thereto that extend downward and connect to the thoracic portion of the system.

Any of the embodiments discussed herein may further include a visor for shielding the user's eyes, forehead, and upper face. For example, the embodiment shown inFIGS. 19A and 19Bis similar to the embodiments shown inFIGS. 10A-11D, and includes a visor802lining the upper portion of the face mask807. The visor802may be made of any lightweight, durable, transparent material. In one example, the visor802is made of clear polycarbonate. The visor802may alternatively be tinted to protect the user's eyes from the sun. By incorporating the visor802, some of the rigid bars in the face masks disclosed herein can be eliminated, thereby reducing the weight of the system and improving visibility for the user.

In another embodiment, as shown inFIG. 20, the face mask907includes an upper portion formed of a clear or tinted transparent visor902, and a lower portion904formed of rigid bars906. In one example, the visor902is made of polycarbonate, or any other lightweight material that is transparent and able to withstand impact without breaking. The bars906may be made of titanium, stainless steel, or any other rigid material that is able to withstand impact. Any of the face masks disclosed herein may be replaced with a face mask907of the style shown inFIG. 20. The face mask907may be attached to any of the hard outer shells of the helmet portions disclosed herein in a manner that allows the face mask907to rotate or pivot relative to the outer shell. For example, the face mask907may be attached to the outer shell with hinges that allow the face mask907to open relative to the outer shell. Alternatively, the face mask907may be attached to the outer shell with pins that allow the face mask907to rotate up relative to the outer shell. Further, the face mask907may have one or more pillars attached thereto that extend downward and connect to the thoracic portion of the system, thereby providing a connection between the helmet portion and the thoracic portion.

In yet another embodiment, as shown inFIG. 21, the face mask1007is a unitary piece having a visor portion1002and a lower portion1004made of rigid bars1006. This face mask1007may be made of any rigid, lightweight material that is able to withstand impact. For example, the face mask1007may be made of polycarbonate. Any of the face masks in the embodiments disclosed herein may be replaced with a face mask1007of the style shown inFIG. 21. The face mask1007may be fixedly, removably, or rotatably attached to the outer shell of the helmet portion of any of the systems disclosed herein. With rotatable attachment, the face mask1007may be attached to the helmet portion so that it is configured to rotate up relative to the helmet portion (similar to the embodiment shown inFIGS. 17A and 17B), or to rotate out relative to the helmet portion (similar to a bird cage door). Further, the face mask1007may have one or more pillars attached thereto that extend downward and connect to the thoracic portion of the system, thereby providing a connection between the helmet portion and the thoracic portion.

FIGS. 22A, 22B, and 22Care, respectively, a front view, front perspective view, and side view illustrating yet another embodiment of the impact diffusion system of the present invention. The framework skeleton of the impact diffusion system2001comprises a first support bar2003extending along the coronal plane from one side of the head, around the top of the head, to the other side of the head. A second support bar2005along the sagittal plane posterior to the head, connects to the first support bar2003at a position2009approximately at the crown of the head when the impact diffusion system is in use. A third support bar2007extends laterally around the back of the head and connects at each end to the first support bar2003at a position approximately below the ears of the wearer, and at its midpoint2030to the lower end of the second support bar2005.

Each of two posterior pillars2011connect to the third support bar2007at a position to the right and to the left, respectively, of the midpoint2030of the third support bar2007, and extend to a connection point2025at the upper part of the back framework2019of the thoracic portion. Connectors2013,2025at each end of the first support bar2003and the posterior pillars2011are detachably connected to connector receptacles2015of the front and back framework2017,2019of the thoracic portion, and may be of any suitable type, such as the “pin-type” quick release mechanism shown inFIGS. 7A and 7B. InFIGS. 22A-22Cthe skeleton of the thoracic portion is shown without padding or outer hard shell covering. In a currently less preferred embodiment of the invention, the headpiece portion and the thoracic portion may be non-detachably joined; that is, without connectors or connection receptacles.

FIG. 23shows a side view of the framework skeleton of the impact diffusion system ofFIGS. 22A-22Cwith a face mask2021attached.FIG. 24Ashow the same side view with the outer protective helmet shell2023attached to the headpiece cage, whileFIG. 24Bshows the same system in front view.

An advantage of the embodiment of the impact diffusions system ofFIGS. 22A-24B(and similar embodiments) may be found in the fact that this design provides strong impact diffusion from all angles, but does not include or require a post or pillar extending downward from the face mask to a connection point on the thoracic portion of the system. In some other embodiments, a post extending downward in this way could present a danger to another player, whose hands, arms or body may more easily become caught in such a post or pillar.

To the extent that a plurality of inventions may be disclosed herein, any such invention shall be understood to have been disclosed herein alone, in combination with other features or inventions disclosed herein, or lacking any feature or features not explicitly disclosed as essential for that invention. For example, the inventions described in this specification can be practiced within elements of, or in combination with, any other features, elements, methods or structures described herein. Additionally, Applicants intend that a feature illustrated herein as being present in a particular embodiment or example may, in other examples of the present invention, be explicitly lacking from the invention, or combinable with features described in other examples or embodiments in this patent application, in a manner not otherwise illustrated in this patent application or present in that particular example. The scope of the invention shall be determined solely by the language of the claims.

The present invention may, in certain examples, be drawn to a unitary helmet portion/pillar/thoracic portion assembly, with and without the inner headgear. In other examples, the invention may be drawn to the helmet portion comprising integrated pillars. In other examples, the invention may be drawn to the thoracic portion comprising the rigid framework. In other examples, the invention may be drawn to the helmet portion and inner headgear. In other examples, the invention may be drawn to methods for protecting the head from experiencing the full impact of a blow thereto, using any, all, or any combination of the elements of the impact diffusing system described herein.

Thus, the various descriptions of the invention provided herein illustrate presently preferred examples of the invention; however, it will be understood that the invention is not limited to the examples provided, or to the specific configurations, shapes, and relation of elements unless the claims specifically indicate otherwise. Based upon the present disclosure a person of ordinary skill in the art will immediately conceive of other alternatives to the specific examples given, such that the present disclosure will be understood to provide a full written description of each of such alternatives as if each had been specifically described.

Each and every patent, published patent application and/or other non-patent publication referred to in this patent application is individually incorporated by reference herein as part of this specification in its entirety.