Football helmet with components additively manufactured to manage impact forces

The invention relates to a multi-step method with a number of processes and sub-processes that interact to allow for the selection, design and/or manufacture of a protective sports helmet for a specific player, or a recreational sports helmet for a specific person wearing the helmet. Once the desired protective sports helmet or recreational sports helmet is selected, information is collected from the individual player or wearer regarding the shape of his/her head and information about the impacts he/she has received while participating in the sport or activity. The collected information is processed to develop a bespoke energy attenuation assembly for use in the protective helmet. The energy attenuation assembly includes at least one energy attenuation member with a unique structural makeup and/or chemical composition. The energy attenuation assembly is purposely engineered to improve comfort and fit, as well as how the helmet responds when an impact or series of impacts are received by the helmet.

CROSS-REFERENCE TO OTHER APPLICATIONS

U.S. Provisional Patent Application Ser. No. 62/770,453, entitled “Football Helmet With Components Additively Manufactured To Optimize The Management Of Energy From Impact Forces,” filed on Nov. 21, 2018, the disclosure of which is hereby incorporated by reference in its entirety for all purposes.

U.S. Design patent application Ser. No. 29/671,111, entitled “Internal Padding Assembly of a Protective Sports Helmet,” filed on Nov. 22, 2018, the disclosure of which is hereby incorporated by reference in its entirety for all purposes.

U.S. patent application Ser. No. 16/543,371 entitled “System And Method For Designing And Manufacturing A Protective Helmet Tailored To A Selected Group Of Helmet Wearers,” filed on Aug. 16, 2019 and U.S. Provisional Patent Application Ser. No. 62/719,130 entitled “System and Methods for Designing and Manufacturing a Protective Sports Helmet Based on Statistical Analysis of Player Head Shapes,” filed on Aug. 16, 2018, the disclosure of these are hereby incorporated by reference in their entirety for all purposes.

U.S. Provisional Patent Application Ser. No. 62/778,559, entitled “Systems And Methods For Providing Training Opportunities Based On Data Collected From Monitoring A Physiological Parameter Of Persons Engaged In Physical Activity,” filed on Dec. 12, 2018, the disclosure of which is hereby incorporated by reference in its entirety for all purposes.

U.S. patent application Ser. No. 15/655,490 entitled “System And Methods For Designing And Manufacturing A Bespoke Protective Sports Helmet,” filed on Jul. 20, 2017 and U.S. Provisional Patent Application Ser. No. 62/364,629 entitled “System And Methods For Designing And Manufacturing A Bespoke Protective Sports Helmet That Provides Improved Comfort And Fit To The Player Wearing The Helmet,” filed on Jul. 20, 2016, the disclosure of these are hereby incorporated by reference in their entirety for all purposes.

U.S. Pat. No. 10,159,296 entitled “System and Method for Custom Forming a Protective Helmet for a Customers Head,” filed on Jan. 15, 2014, U.S. Provisional Patent Application Ser. No. 61/754,469 entitled “System and method for custom forming sports equipment for a user's body part,” filed Jan. 18, 2013, U.S. Provisional Patent Application Ser. No. 61/812,666 entitled “System and Method for Custom Forming a Protective Helmet for a User's Head,” filed Apr. 16, 2013, U.S. Provisional Patent Application Ser. No. 61/875,603 entitled “Method and System for Creating a Consistent Test Line within Current Standards with Variable Custom Headforms,” filed Sep. 9, 2013, and U.S. Provisional Patent Application Ser. No. 61/883,087 entitled “System and Method for Custom Forming a Protective Helmet for a Wearer's Head,” filed Sep. 26, 2013, the disclosure of these are hereby incorporated by reference in their entirety for all purposes.

U.S. Pat. No. 9,314,063 entitled “Football Helmet with Impact Attenuation System,” filed on Feb. 12, 2014 and U.S. Provisional Patent Application Ser. No. 61/763,802 entitled “Protective Sports Helmet with Engineered Energy Dispersion System,” filed on Feb. 12, 2013, the disclosure of these are hereby incorporated by reference in its entirety for all purposes.

U.S. Design Pat. D850,011 entitled “Internal Padding Assembly of A Protective Sports Helmet,” filed on Jul. 20, 2017, U.S. Design Pat. D850,012 entitled “Internal Padding Assembly of A Protective Sports Helmet,” filed on Jul. 20, 2017, and U.S. Design Pat. D850,013 entitled “Internal Padding Assembly of A Protective Sports Helmet,” filed on Jul. 20, 2017, the disclosure of these are hereby incorporated by reference in their entirety for all purposes.

U.S. Design Pat. D603,099 entitled “Sports Helmet,” filed on Oct. 8, 2008, U.S. Design Pat. D764,716 entitled “Football Helmet,” filed on Feb. 12, 2014, and U.S. Pat. No. 9,289,024 entitled “Protective Sports Helmet,” filed on May 2, 2011, the disclosure of these are hereby incorporated by reference in their entirety for all purposes.

TECHNICAL FIELD

The invention relates to a protective sports helmet purposely engineered to improve comfort and fit, as well as how the helmet responds when an impact or series of impacts are received by the helmet when worn by a player. Specifically, this invention relates to a football helmet, where at least one energy attenuation component is specifically designed and manufactured using an additive manufacturing process to adjust how the helmet fits and responds to impact forces received by the helmet when it is worn by a player.

BACKGROUND OF THE INVENTION

Protective sports helmets, including those worn during the play of a contact sports, such as football, hockey, and lacrosse, typically include an outer shell, an internal pad assembly coupled to an interior surface of the shell, a faceguard or face mask, and a chin protector or strap that releasably secures the helmet on the wearer's head. However, most traditional helmets do not use advanced techniques to create a helmet that is specifically designed to respond in a certain manner when an impact or series of impacts are received by the helmet. Additionally, most traditional helmets do not contain components that are specifically selected or tailored to a particular player's playing level, position, medical history and/or to at least one of the player's anatomical features.

Accordingly, there is an unmet need for a helmet that uses advanced structures (e.g., lattice cell types), advanced materials with tailored chemical compositions (e.g., specific light sensitive polymers), and advanced helmet design/manufacturing techniques (e.g., finite element analysis, neural networks, additive manufacturing) to create a helmet that is specifically tailored to a particular player's playing level, position, medical history and/or to at least one of the player's anatomical features (such as the player's head topography). Additionally, there is also an unmet need to create a helmet that contains components that are specifically tailored to a particular player's playing level, position, and/or to at least one of the player's anatomical features (such as the player's head topography).

SUMMARY OF THE INVENTION

This disclosure generally provides a multi-step method with a number of processes and sub-processes that interact to allow for the selection, design and/or manufacture of (i) a protective contact sports helmet for a specific player, or (ii) a protective recreational sports helmet for a specific person wearing the helmet.

In the context of a protective contact sports helmet, the inventive multi-step method starts with the selection of a desired sports helmet and then collecting information from the individual player. In the context of a protective recreational sports helmet, the inventive multi-step method starts with the selection of a desired recreational sports helmet and then collecting information from the individual wearer. This collection of information may include information about the shape of a player's head and information about the impacts the player has received while participating in the sport or activity. Once this information is collected, it can be used to: (i) recommend a stock helmet or stock helmet component that best matches the player's or wearer's collected and processed information or (ii) develop a bespoke energy attenuation assembly for use in the contact sports helmet or the recreational sports helmet based on the player's or wearer's collected and processed information, respectively.

The contact sports helmet and the recreational sports helmet each include an energy attenuation assembly with one or more bespoke energy attenuation members, where the energy attenuation member includes a region with a structural makeup and/or chemical composition that is different from other regions of that same member. Alternatively, the energy attenuation assembly includes a first member with a first structural makeup and/or chemical composition that differs from a second structural makeup and/or chemical composition of a second member of the attenuation assembly. The energy attenuation assembly could include a first member with a first region with a structural makeup and/or chemical composition that is different from a second region of the first member, and a second member with a first region with a structural makeup and/or chemical composition that is different from a second region of the second member and the first and second regions of the first member.

To efficiently create members of the energy attenuation assembly having differing structural makeups and/or chemical compositions, the development process involves the usage of advanced structures (e.g., lattice cell types), advanced materials with tailored chemical compositions (e.g., specific light sensitive polymers), and advanced helmet design/manufacturing techniques (e.g., finite element analysis, neural networks, additive manufacturing) are utilized while accounting for the player's specific playing level, position, medical history and/or to at least one of the player's anatomical features. The energy attenuation assembly is positioned within an outer shell of the protective contact sports helmet or the protective recreational sports helmet. When the contact sports helmet is configured for use while playing American football, hockey or lacrosse, the helmet includes a face guard or facemask and a chin strap.

DETAILED DESCRIPTION

While this disclosure includes a number of embodiments in many different forms, there is shown in the drawings and will herein be described in detail particular embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principles of the disclosed methods and systems, and is not intended to limit the broad aspects of the disclosed concepts to the embodiments illustrated. As will be realized, the disclosed methods and systems are capable of other and different configurations and several details are capable of being modified all without departing from the scope of the disclosed methods and systems. For example, one or more of the following embodiments, in part or whole, may be combined consistent with the disclosed methods and systems. As such, one or more steps from the flow charts or components in the Figures may be selectively omitted and/or combined consistent with the disclosed methods and systems. Accordingly, the drawings, flow charts and detailed description are to be regarded as illustrative in nature, not restrictive or limiting.

This section identifies a number of terms and definitions that are used throughout the Application. The term “player” is a person who wears the protective sports helmet while engaged in practice or game play of the sport. The term “helmet wearer” or “wearer” is a player who is wearing the helmet. The term “designer” is a person who designs, tests, or manufactures the helmet.

A “protective sports helmet” is a type of protective equipment that a player or participant wears on his/her head while engaged in an activity, such as the play of a sport or an activity.

A “protective contact sports helmet” or “contact sports helmet” is a type of protective sports helmet that the player wears while he/she is engaged in the play of the sport, such as American football, hockey or lacrosse, that typically requires a team of players. It is common for the rules and the regulations of the particular contact sport to mandate that the player wear the contact sports helmet while he/she is engaged in playing the sport. Contact sports helmets typically must comply with safety regulations promulgated by a governing body, such as NOCSAE for football helmets.

A “protective recreational sports helmet” or “recreational sports helmet” is a type of protective sports helmet that is worn by the wearer while he/she is participating in a recreational activity such as cycling, climbing sports, skiing, snowboarding, motorsports or motorcycling, that typically can be done by an individual wearer. Recreational sports helmets typically must also comply with safety regulations promulgated by a governing body, such as ASTM/ANSI regulations for cycling helmets and Department of Transport (DOT) for motorsports helmets and motorcycling helmets.

An “energy attenuation assembly” is an internal assembly of energy attenuating members that are designed to collectively interact to enable the protective sports equipment, for example, the contact sports helmet or recreational sports helmet to attenuate energies, such as linear acceleration and/or rotational acceleration, from impacts received by the sports helmet. As detailed below, the energy attenuation assembly can include multiple attenuating members that are designed to optimize the performance of the energy attenuation assembly for the helmet.

An “energy attenuation member(s)” is a component of the energy attenuation assembly that is installed within the helmet. The energy attenuation member is a three-dimensional (3D) component that has both a volume and an outer periphery. The volume and outer periphery are defined by an X, Y and Z Cartesian coordinate system where the Z direction is defined out of plane to provide the energy attenuation member with a height or thickness. When the energy attenuation member is part of an assembly installed within a contact sports helmet, the Z-direction thickness represents the dimension of the energy attenuation member between the player's head and an inner surface of a shell of the sports helmet when the sports helmet is actually worn on the player's head.

The term “member region” is a zone or volume of an energy attenuation member, where the member region has properties, including (i) lattice cells, (ii) lattice densities, (iii) lattice angles, (iv) mechanical properties and/or (v) chemical properties. A single energy attenuation member can include one or more member regions, where region A has a first set of properties (i)-(v) and region B has a second set of properties (i)-(v) that differ. It should be understood that if there is more than a minor variation in the properties (i)-(v), then there are two distinct member regions. For example, if there are differences in the lattice cell's geometry, then those lattice cells identify two distinct member regions.

The term “lattice cell” is the simplest repeating unit contained within a member region of an energy attenuation member. The lattice cell has a geometry that is due to the type of cell unit. It should be understood that various types of lattice cell units are contemplated by this disclosure, some of which are shown inFIG. 39. In that Figure, some of the lattice cell types are comprised of a number of lattice “struts” which are elongated structures that intersect with one another to form the specific geometry of the lattice cell. Depending upon design parameters, the thicknesses and/or length of the lattice struts can be altered in a particular lattice cell. However, that alteration should not change the designation of the lattice cell (e.g., increasing the strut thickness of a strut-based lattice should not change its designation). It should further be understood that minor variations in the geometry of the lattice cells due to the manufacturing process or tolerances do not result in a new categorization of the lattice cell.

The term “lattice density” is the density of a particular lattice cell. The lattice density can vary based upon a number of design parameters, including but not limited to the configuration of the struts that form the lattice cell. It should be understood that minor variations in the lattice densities due to the manufacturing process or tolerances manufacturing process or tolerances do not result in a new categorization of the lattice density.

The term “lattice angle” is the angle at which a lattice cell is positioned normal to a reference surface of the member. It should be understood that minor variations in the lattice angles due to the manufacturing process or tolerances manufacturing process or tolerances do not result in a new categorization of the lattice angle(s).

The term “anatomical features” can include any one or any combination of the following: (i) dimensions, (ii) topography and/or (iii) contours of the player's body part including, but not limited to, the player's skull, facial region, eye region and jaw region. Because the disclosed helmet is worn on the player's head and the energy attenuation assembly makes contact with the player's hair, the “anatomical features” term also includes the type, amount and volume of the player's hair or lack thereof. For example, some players have long hair, while other players have no hair (i.e., are bald). While the present disclosure, as will be discussed in detail below, is capable of being applied to any body part of an individual, it has particular application the human head. Therefore, any reference to a body part is understood to encompass the head, and any reference to the head alone is intended to include applicability to any body part. For ease of discussion and illustration, discussion of the prior art and the present disclosure is directed to the human head, by way of example, and is not intended to limit the scope of discussion to the human head.

The term “custom shaped energy attenuation assembly model” or “CS model” is a digital or computerized model of the energy attenuation assembly that has been altered based upon information gathered and processed from the player's profile220.99(see below) that includes a head model.

The term “custom performance energy attenuation assembly model” or “CP model” is a digital or computerized model of the energy attenuation assembly that has been altered based upon information gathered and processed from the player's profile320.99(see below) that includes an impact matrix.

The term “custom performance and custom shaped energy attenuation assembly model” or “CP+CS model” is a digital or computerized model of the energy attenuation assembly that has been altered or created based upon information gathered and processed from the player's profile120.99(see below) that includes both a head model and an impact matrix.

The term “player specific helmet model” is a digital or computerized model of a protective sports helmet that is derived from one of the CP+CS model, CP model, or CS model. In contrast to the CP+CS model, CP model, and CS model that is not designed to be manufactured, the player specific helmet model is designed to be manufactured to create a helmet to be worn by the player or wearer.

The term “complete stock helmet model” is a digital or computerized model of the protective sports helmet that has been designed and developed in connection with U.S. patent application Ser. No. 16/543,371. Specifically, in U.S. patent application Ser. No. 16/543,371 the complete stock helmet model was referred to as the “complete helmet model.”

The term “stock helmet(s)” is a helmet that is pre-manufactured and designed for a select “player group” from amongst a larger population of helmet wearers. The stock helmet is not specifically designed or bespoke for one player or wearer. Stock helmets provide a number of benefits to the helmet manufacturer, including but not limited to improved efficiencies in manufacturing, raw material usage and inventory management.

The term “player group” is a group or subset of players or wearers that are part of a larger population of players or wearers who participate in the sporting activity. In the context of contact sports helmets, the player group is a subset of players wearing helmets from amongst the broader group of players wearing helmets during the play of the contact sport.

The term “stock helmet components” are pre-manufactured components for protective sports helmets that are not specifically designed for one player or wearer, but instead are designed for a select player group from amongst a larger population of players or wearers.

The term “player specific helmet” is a bespoke protective sports helmet, with an energy attenuation assembly, that is purposely designed, configured and manufactured to match the player or wearer's characteristics, including his/her: (i) anatomical features of the head, (ii) impact history, or (iii) both the anatomical features of the head and impact history.

The term “player specific helmet” is a bespoke protective sports helmet, with an energy attenuation assembly, that is purposely designed, configured and manufactured to match the player or wearer's characteristics, including his/her: (i) anatomical features of the head, (ii) impact history, or (iii) both the anatomical features of the head and impact history.

B. Selection of a Protective Sports Helmet

A multi-step method 1 including a number of processes and sub-processes that interact to allow for the selection, design and/or manufacture of (i) a protective contact sports helmet for a specific player, or (ii) a protective recreational sports helmet for a specific person wearing the helmet. The multi-step method 1 begins with the player selecting a protective sports helmet from a plurality of protective sports helmets using an internet enabled device in step50. The information associated with the selected protective sports helmet: (i) is used to determine what information or data is needed from the player and (ii) will inform various parameters of the helmet, including but not limited to, the topography of an interior surface of the energy attenuation assembly, how the energy attenuation assembly is manufactured, or the structural and/or chemical composition of the energy attenuation assembly. It is understood that if the method 1 includes a step or process that is irrelevant to the selection, design and/or manufacture of the contact sports helmet or the recreational sports helmet, then that step or process can be omitted without negatively impacting the functionality of the method 1.

As shown inFIG. 2, this process is started50.1by an operator or player opening up a software application or browser to select or configure a protective sports helmet. If the operator or player does not have the software application downloaded on their device, they can download it from an internet database (e.g., iTunes, Google Play, or etc.). Alternatively, the operator or player may go to the protective sports helmet configurator URL using an internet enabled device (e.g., a computer or cellphone). Upon opening the protective sports helmet configurator, the operator may be requested to input information about the player (e.g., player's name, age, playing level, position, and/or injury history). Once this information is entered into the system, the player P can have the system find a previously created profile that includes information that is associated with the player or the player can create a new profile. After the player's profile is populated with the available information, the protective sports helmet configurator prompts the operator or player P to select the desired protective sports helmet from a plurality of protective sports helmets. It should be understood that additional information may be added to the player profile during the process of selecting a protective sports helmet, such as shape information from a scan of the player.

Next, the protective sports helmet configurator allows the operator or player to select: (i) a new energy attenuation assembly2000,3000for a previously acquired helmet by selecting50.10or (ii) a new helmet1000by selecting50.50. If the operator or player selects the new energy attenuation assembly2000,3000for a previously acquired helmet by selecting50.10, the operator or player will be required to certify the condition of the previously acquired helmet50.12. This may be done by requiring the operator or player to input the model of the helmet, input the year the helmet was bought, upload pictures of the helmet, including all labels, and/or attest to the condition of the helmet. If the protective sports helmet configurator determines that the helmet is not in an acceptable condition, then the protective sports helmet configurator may suggest to the operator or player that they purchase a new helmet50.14.

If the protective sports helmet configurator determines that the helmet is in an acceptable condition and is capable of receiving a new energy attenuation assembly2000,3000in step50.16, then the protective sports helmet configurator allows the operator or player to select the topography or shape of the inner surface of the energy attenuation assembly2000,3000. In particular, the player may select: (i) a stock shaped energy attenuation assembly2000by selecting50.18or (ii) a custom shaped energy attenuation assembly3000by selecting50.22. If the operator or player picks the stock shaped energy attenuation assembly2000by selecting50.18, then the system will ask the user to input/acquire/collect shape information about the player's body part and specifically the player's head region. This shape information will be utilized by the system in the following steps to suggest the stock energy attenuation assembly2000that will best fit the player's head. Next, the operator or player may select how the energy attenuation assembly2000is manufactured. For example, the operator or player may select: (i) a standard method of manufacturing the energy attenuation assembly, including foam molding, by selecting50.20or (ii) a state-of-the-art method of manufacturing the energy attenuation assembly2000, including an additive manufacturing process, by selecting50.26.

Alternatively, if the operator or player selects custom shaped energy attenuation assembly3000in step50.22, then the system will ask the user to input/acquire/collect shape information about the player's body part and specifically the player's head region. This shape information will be utilized by the system in the following steps to select the energy attenuation assembly2000that will best fit the player's head and then to modify the selected energy attenuation assembly2000to create a custom energy attenuation assembly3000. Next, the operator or player may select how the energy attenuation assembly3000is manufactured. For example, the operator or player may select: (i) an advanced method of manufacturing the energy attenuation assembly, including the custom molding process (e.g. the process disclosed within U.S. patent application Ser. No. 15/655,490), by selecting50.24or (ii) a state-of-the-art method of manufacturing the energy attenuation assembly3000, including an additive manufacturing process, by selecting50.26.

Next, if the operator or player selected the additive manufactured energy attenuation assembly2000,3000or the custom molded energy attenuation assembly by selecting50.24,50.26, the operator or player can then select the energy attenuation assembly performance type in steps50.28,50.30,50.32,50.34,50.36. Specifically, the operator or player can choose from one of the following performance types: (i) standard50.28, (ii) type 1 (e.g., position specific)50.30, (iii) type 2 (e.g., playing level specific)50.32, (iv) type 3 (e.g., position and playing level specific)50.34, or (v) custom (e.g., custom based on the specific player's playing level, position, and playing style)50.36. If the operator or player selects type custom50.36, then the system1will ask the user to input/acquire/collect impact information about the player. This impact information will be utilized by the system in the following steps to: (i) select the energy attenuation assembly2000that best matches the player's player style or (ii) select the energy attenuation assembly2000that best matches the player's player style and then to modify the selected energy attenuation assembly2000to create a custom energy attenuation assembly3000.

As will be discussed in greater detail below, a position-specific energy attenuation assembly2000,3000that is designed for a quarterback may have additional material in the rear of the energy attenuation assembly2000,3000in comparison to a position-specific energy attenuation assembly2000,3000that is designed for a lineman. Likewise, a position-specific energy attenuation assembly2000,3000that is designed for a lineman may include a material that is softer or less dense in the front of the energy attenuation assembly2000,3000in comparison to a position-specific energy attenuation assembly2000,3000that is designed for a quarterback. Also, a playing level specific energy attenuation assembly2000,3000that is designed for a youth player may include additional material and/or may be made from a material that is softer or less dense than an energy attenuation assembly2000,3000that is designed for an NFL player.

Alternatively, if the operator or player picks a new helmet1000by selecting50.50, the operator or player will be asked to select a helmet type50.52. Specifically, the operator or player will be asked to choose from the available helmets, where one type may be Riddell's Speed helmet50.54, a second type may be Riddell's SpeedFlex helmet50.56, and a third type may be another type of helmet50.58. It should be understood that more or less helmet shell designs may be provided to the operator or player. Next, step50.60allows the operator or player to select the topography or shape of the inner surface of the energy attenuation assembly2000,3000. In particular, the player may select: (i) a stock shaped energy attenuation assembly2000by selecting50.62or (ii) a custom shaped energy attenuation assembly3000by selecting50.66. If the operator or player picks the stock shaped energy attenuation assembly2000by selecting50.62, then the system will ask the user to input/acquire/collect shape information about the player's body part and specifically the player's head region. Next, the operator or player may select how the energy attenuation assembly2000is manufactured. For example, the operator or player may select: (i) a standard method of manufacturing the energy attenuation assembly, including foam molding, by selecting50.64or (ii) a state-of-the-art method of manufacturing the energy attenuation assembly2000, including an additive manufacturing process, by selecting50.70.

Alternatively, if the operator or player selects custom shaped energy attenuation assembly3000in step50.66, then the system will ask the user to input/acquire/collect shape information about the player's body part and specifically the player's head region. Next, the operator or player may select how the energy attenuation assembly3000is manufactured. For example, the operator or player may select: (i) an advanced method of manufacturing the energy attenuation assembly, including the custom molding process (e.g, the process disclosed within U.S. patent application Ser. No. 15/655,490), by selecting50.68or (ii) a state-of-the-art method of manufacturing the energy attenuation assembly3000, including an additive manufacturing process, by selecting50.70.

Next, if the operator or player selected the additive manufactured energy attenuation assembly2000,3000or the custom molded energy attenuation assembly by selecting50.68,50.70, the operator or player can then select the energy attenuation assembly performance type in steps50.72,50.74,50.76,50.78,50.80. Specifically, the operator or player can choose from one of the following performance types: (i) standard50.72, (ii) type 1 (e.g., position specific)50.74, (iii) type 2 (e.g., playing level specific)50.76, (iv) type 3 (e.g., position and playing level specific)50.78, or (v) custom (e.g., custom based on the specific player's playing level, position, and playing style)50.80. If the operator or player selects type custom50.80, then the system1will ask the user to input/acquire/collect impact information about the player. This impact information will be utilized by the system1in the following steps to: (i) select the energy attenuation assembly2000that best matches the player's player style or (ii) select the energy attenuation assembly2000that best matches the player's player style and then to modify the selected energy attenuation assembly2000to create a custom energy attenuation assembly3000.

Next, the protective sports helmet configurator allows the operator or player to select the faceguard's configuration or shape in50.82, which can include the number and position of both the vertical members and lateral members. In one embodiment, the operator or player may select the faceguard's shape from a predetermined plurality of faceguard shapes. In an alternative embodiment, the operator or player can design their own faceguard200by selecting the placement of specific members of the faceguard200. Once the operator or player is done with their custom designed faceguard, the protective sports helmet configurator will test the design and confirm that the design will meet the helmet standard. If the design will not meet the helmet standard, alternative designs to the custom faceguard will be suggested to the operator or player.

Next, the protective sports helmet configurator allows the operator or player to select the chinstrap type in50.84. After the chinstrap type is selected in50.84, the protective sports helmet configurator allows the operator or player to select the color of the shell, faceguard, chinstrap, and energy attenuation assembly2000,3000. Once the operator or player has selected the protective sports helmet from the protective sports helmet configurator, the protective sports helmet configurator sends or loads the selected protective sports helmet on a scanning apparatus110.4.2,210.4.2. Information about the selected protective sports helmet will be used by the scanning apparatus110.4.2,210.4.2in order to determine what type of scan or scans are necessary. For example, if the operator or player selected an energy attenuation assembly2000that has a non-custom or preset inner topography, then the scanning apparatus110.4.2,210.4.2may determine that the quality of the scan does not have to be as high in comparison to a scan needed to manufacture energy attenuation assembly with a custom inner surface. Alternatively, if the operator or player selected an energy attenuation assembly2000,3000that has a custom performance type, the protective sports helmet configurator will check to ensure that the system has enough data about the player's playing style to design this energy attenuation assembly2000,3000.

C. Collecting Information

After the desired protective sports helmet is selected in step50, the multi-step method 1 continues by collecting information about the player in steps100,110,210,300, which may include information about the shape of a player's head and the impacts the player receives while participating in the sport.

1. Collecting Impact Information

Referring toFIG. 1, steps100,300describe acquiring information about impacts the players experience while participating in an activity (e.g., playing a football game). One example of a method of collecting this impact information is described withinFIGS. 3A-3B. In step100.2,200.2, an impact sensor system is utilized to carry out the steps in the method shown inFIGS. 3A-3B.FIG. 4illustrates an exemplary system100.2,300.2that includes: (i) helmets1000that each have an in-helmet unit (IHU)100.2.4,300.2.4, (ii) a receiving device100.2.6,300.2.6, which in this embodiment may be an alerting unit100.2.6.2,300.2.6.2, (iii) a remote terminal100.2.8,300.2.8, (iv) a team database100.2.10,300.2.10, and (v) a national database100.2.12,300.2.12. The IHU100.2.4,300.2.4may be specifically designed and programmed to: (i) measure and record impact information, (ii) analyze the recorded information using the algorithm shown inFIGS. 3A-3B, and (iii) depending on the outcome of the algorithm shown inFIGS. 3A-3B, transmit the recorded information to a receiving device100.2.6,300.2.6that is remote from the THU100.2.4,300.2.4.

FIG. 5illustrates an exemplary schematic of the THU100.2.4,300.2.4. As shown, the control module100.2.4.2,300.2.4.2is connected to each sensor100.2.4.4a-e,300.2.4.4a-evia separate leads100.2.4.6a-e,300.2.4.6a-e. The five distinct sensors100.2.4.4a-e,300.2.4.4a-emay be placed at the following locations on a player's head: top, left, right, front, and back. The control module100.2.4.2,300.2.4.2includes a signal conditioner100.2.4.8,300.2.4.8, a filter100.2.4.10,300.2.4.10, a microcontroller or microprocessor100.2.4.12,300.2.4.12, a telemetry element100.2.4.14,300.2.4.14, an encoder100.2.4.16,300.2.4.16, and a power source100.2.4.18,300.2.4.18. The control module100.2.4.2,300.2.4.2includes a shake sensor100.2.4.20,300.2.4.20that may be used to turn the IHU100.2.4,300.2.4ON or OFF based on a specific shake pattern of the player helmet20. Alternatively, the IHU100.2.4,300.2.4may have control buttons, such as a power button and a configuration button, for example. Additional information about the positioning and configuration of the IHU100.2.4,300.2.4is described within U.S. Pat. No. 10,105,076 and U.S. Provisional Application62/364,629, both of which are fully incorporated herein by reference.

Returning toFIG. 3A, the IHU100.2.4,300.2.4continually monitors for a value from any sensor100.2.4.4a-e,300.2.4.4a-ethat exceeds a predetermined noise threshold, which is programmed into the IHU100.2.4,300.2.4. As shown in step100.4,300.4, once the IHU100.2.4,300.2.4determines that a sensor100.2.4.4a-e,300.2.4.4a-ehas recorded a value that is greater than the predetermined noise threshold, then an impact has been detected. The microcontroller100.2.4.12,300.2.4.12wakes up to record information from all sensors100.2.4.4a-e,300.2.4.4a-eand perform both algorithms shown inFIGS. 3A-3B. The first algorithm or head impact exposure (HIE) algorithm100.10,300.10does not weight the impact magnitude value based on the location of the impact, while the second algorithm or alert algorithm100.50,300.50weights the impact magnitude value based on the location of the impact. The first algorithm or HIE algorithm100.10,300.10compares the impact magnitude value to a 1stthreshold or an impact matrix threshold in step100.10.2,300.10.2. The 1stthreshold or an impact matrix threshold is set between 1 g and 80 gs and preferably between 5 gs and 30 gs. If the impact magnitude value is less than the impact matrix threshold, than the microcontroller100.2.4.12,300.2.4.12will disregard the impact magnitude value shown in step100.10.10,300.10.10. However, if the impact magnitude value is greater than the impact matrix threshold, than the microcontroller100.2.4.12,300.2.4.12will add the impact magnitude value to the impact matrix in step100.10.4,300.10.4.

An exemplary player impact matrix120.2.75,320.2.75is shown inFIG. 13. Specifically, the exemplary impact matrix120.2.75,320.2.75is comprised of 5 columns and 7 rows, where the 5 columns correspond to the location of the impact on the player's head (e.g., front, back, left, right, and top) and the 7 rows correspond to the severity of the impact (e.g., 1st, 2nd, 3rd, 4th, 5thseverity, single impact alert, or cumulative impact alert). Each of these severity values (e.g., 1st, 2nd, 3rd, 4thor 5th) corresponds to a range of impact magnitude values. For example, the 1strange may include impact magnitude values between the impact matrix threshold and the 50thpercentile of historical impact magnitude values for players of similar position and playing level. The 2ndrange may include impact magnitude values between the 51stpercentile and the 65thpercentile of historical impact magnitude values for players of similar position and playing level. The 3rdrange may include impact magnitude values between the 66thpercentile and the 85thpercentile of historical impact magnitude values for players of similar position and playing level. The 4thrange may include impact magnitude values between the 86thpercentile and the 95thpercentile of historical impact magnitude values for players of similar position and playing level. The 5thrange may include impact magnitude values above the 95thpercentile of historical impact magnitude values for players of similar position and playing level. The single impact alerts and the cumulative impact alerts are based upon a second algorithm or alert algorithm100.50,300.50. It should be understood that these percentile ranges are based on historical impact magnitude values that have been collected using the proprietary technologies owned by the assignee of the present Application and are disclosed in U.S. Pat. Nos. 10,105,076, 9,622,661, 8,797,165, and 8,548,768, each of which is fully incorporated by reference herein. It should be understood that these values may be updated in light of additional impact information that has been collected by this system or other similar systems.

Returning toFIG. 3A, once the microcontroller100.2.4.12,300.2.4.12has added the impact magnitude value to the impact matrix in step100.10.4,300.10.4, the microcontroller100.2.4.12,300.2.4.12determines if a 1stpredefined amount of time or an impact matrix transmit time period has passed from the time the IHU100.2.4,300.2.4last transmitted the impact matrix to a receiving device100.2.6,300.2.6. The impact matrix transmit time period may be set to any time, preferably it is set between one second and 90 days and most preferably between 30 seconds and 1 hour. If the amount of time that has passed since the unit last transmitted the impact matrix to a receiving device100.2.6,300.2.6is less than the impact matrix transmit time period, then the microcontroller100.2.4.12,300.2.4.12will perform no additional steps, as shown in step100.10.10,300.10.10. However, if the amount of time that has passed since the unit last transmitted the impact matrix to a receiving device100.2.6,300.2.6is greater than the impact matrix transmit time period, then the control module100.2.4.2,300.2.4.2of the THU100.2.4,300.2.4will transmit the impact matrix from the THU100.2.4,300.2.4to a receiving device100.2.6,300.2.6(e.g., an alert unit100.2.6.2,300.2.6.2) in step536. Upon the completion of this decision, the THU100.2.4,300.2.4has finished performing the HIE algorithm100.10,300.10.

While the THU100.2.4,300.2.4is performing the HIE algorithm100.10,300.10, the THU100.2.4,300.2.4is also performing the alert algorithm100.50,300.50shown inFIG. 3B. Referring toFIG. 3B, the microcontroller100.2.4.12,300.2.4.12will calculate an impact value in step100.50.2,300.50.2. In one embodiment, this is done by first determining the linear acceleration, rotational acceleration, head injury criterion (HIC), and the Gadd severity index (GSI) for the given impact. The algorithms used to calculate these values are described in Crisco J J, et al. An Algorithm for Estimating Acceleration Magnitude and Impact Location Using Multiple Nonorthogonal Single-Axis Accelerometers.J BioMech Eng.2004; 126(1), Duma S M, et al. Analysis of Real-time Head Accelerations in Collegiate Football Players.Clin Sport Med.2005; 15(1):3-8, Brolinson, P. G., et al. Analysis of Linear Head Accelerations from Collegiate Football Impacts.Current Sports Medicine Reports, vol. 5, no. 1, 2006, pp. 23-28, and Greenwald R M, et al. Head impact severity measures for evaluating mild traumatic brain injury risk exposure.Neurosurgery.2008; 62(4):789-798, the disclosure of which is hereby incorporated by reference in its entirety for all purposes. Once the linear acceleration, rotational acceleration, head injury criterion (HIC), and the Gadd severity index (GSI) are calculated for a given impact, these scores are weighted according to the algorithm set forth in Greenwald R M, et al. Head impact severity measures for evaluating mild traumatic brain injury risk exposure.Neurosurgery.2008; 62(4):789-798, the disclosure of which is hereby incorporated by reference in its entirety for all purposes. This resulting weighted value is a HITsp value for the given impact, which will be the calculated impact value in this first embodiment. While not diagnostic of injury, HITsp has been shown to be more sensitive and specific to diagnose concussions than any of the component measures alone. Specifically, HITsp has been shown to be 50% more sensitive to predict a subsequently diagnosed concussion than the usage of any individual measure by itself (e.g., linear acceleration).

In another embodiment, the calculated impact value may be equal to the linear acceleration for the given impact. In a further embodiment, the calculated impact value may be equal to the HIC score for the given impact. In another embodiment, the calculated impact value may be equal to the rotational acceleration for a given impact. In another embodiment, the impact value may be equal to the linear acceleration weighted by a combination of impact location and impact duration. In another embodiment, the impact value may be equal to the weighted combination of linear acceleration, rotational acceleration, HIC, GSI, impact location, impact duration, impact direction. In another embodiment, the impact value may be equal to a value that is determined by a learning algorithm that is taught using historical information and diagnosed injuries. In even a further embodiment, the impact value may be equal to any combination of the above.

Referring toFIG. 3B, once the impact value is calculated in step100.50.2,300.50.2by the microcontroller100.2.4.12,300.2.4.12, the impact value is compared against a 2ndthreshold or high magnitude impact threshold in step100.50.4,300.50.4. This high magnitude impact threshold may be set to the 95thpercentile for impacts recorded by players of similar playing level (e.g., youth, high school, college and professional players) and similar position (e.g., offensive line, running backs, quarterback, wide receivers, defensive linemen, linebackers, defensive backs and special teams). If the impact value is less than the high magnitude impact threshold, than the microcontroller100.2.4.12,300.2.4.12will not perform any additional operations, as shown in step100.50.6,300.50.6. However, if the impact value is greater than the high magnitude impact threshold, than the impact value will be added to the cumulative impact value in step100.50.6,300.50.6and compared against a 3rdthreshold or single impact alert threshold in step100.50.18,300.50.18. This single impact alert threshold may be set to the 99thpercentile for impacts recorded by players of similar playing level and position. It should be understood that all percentiles (e.g., 95thand 99th) contained in this application are based on historical impact magnitude values that have been collected using the proprietary technologies owned by the assignee of the present Application and are disclosed in U.S. Pat. Nos. 10,105,076, 9,622,661, 8,797,165, and 8,548,768, each of which is fully incorporated by reference herein. However, it should be understood that these percentiles may be updated in light of additional impact information that has been collected by this system or other systems.

Referring toFIG. 3B, if the impact value is greater than the single impact alert threshold, the control module100.2.4.2,300.2.4.2transmits alert information that is associated with the single impact alert to the receiving device100.2.6,300.2.6(e.g., an alert unit100.2.6.2,300.2.6.2) in step100.50.22,300.50.22. The alert information may include, but is not limited to: (i) the impact value (e.g., graphical or non-graphical display of the magnitude of the impact), (ii) impact location (e.g., graphical or non-graphical), (iii) impact time, (iv) impact direction, (v) player's unique identifier, (vi) alert type, (vii) player's heart rate, (viii) player's temperature and (ix) other relevant information. If the impact value is less than the single impact alert threshold, the microcontroller100.2.4.12,300.2.4.12will not perform any additional steps100.50.20,300.50.20along this path of the algorithm100.50,300.50.

While the microcontroller100.2.4.12,300.2.4.12is determining whether the impact value is greater than the single impact alert threshold in step100.50.18,300.50.18, the microcontroller100.2.4.12,300.2.4.12also calculates a weighted cumulative impact value that includes this new impact value, in step100.50.10,300.50.10shown inFIG. 3B. Specifically, the weighted cumulative impact value is calculated based on a weighted average of every relevant impact value that is over a 2ndthreshold or high magnitude impact threshold. To determine this weighted average, every impact value that is over a 2ndthreshold is weighted by a decaying factor. For example, an impact that was recorded 4 days ago maybe multiplied by 0.4 decaying factor, thereby reducing the magnitude level of this impact. After the weighted impact values are determined, these values are summed together to generate the weighted cumulative impact value. It should be understood that the microcontroller100.2.4.12,300.2.4.12will exclude irrelevant impact values that are old enough to cause their weighted impact value to be zero due to the decaying factor. For example, if the decaying factor for an impact that is over 7 days old is 0; then regardless of the impact value, this impact is irrelevant to this calculation and will not be included within this calculation. One skilled in the art recognizes that weighting variables (e.g., time window, decay function, input threshold) are adjustable.

Once the weighted cumulative impact value has been calculated in step100.50.10,300.50.10inFIG. 3B, this value is compared against a 4ththreshold or a cumulative impact alert threshold in step100.50.12,300.50.12. This cumulative impact alert threshold may be set to the 95thpercentile for weighted cumulative impact values recorded by players of similar playing level and position. If the weighted cumulative impact value is less than the cumulative impact alert threshold, than the microcontroller100.2.4.12,300.2.4.12will not perform any additional steps100.50.16,300.50.16. However, if the weighted cumulative impact value is greater than the cumulative impact value threshold, the control module100.2.4.2,300.2.4.2of the IHU100.2.4,300.2.4transmits alert information that is associated with a cumulative impact alert to the receiving device100.2.6,300.2.6(e.g., an alert unit100.2.6.2,300.2.6.2) in step100.50.14,300.50.14. As discussed above, the alert information may include, but is not limited to: (i) the impact value (e.g., graphical or non-graphical display of the magnitude of the impact), (ii) impact location (e.g., graphical or non-graphical), (iii) impact time, (iv) impact direction, (v) player's unique identifier, (vi) alert type, (vii) player's heart rate, (viii) player's temperature and (ix) other relevant information. Upon the completion of this decision, the IHU100.2.4,300.2.4has finished performing the alert algorithm100.50,300.50.

Referring toFIG. 4, once the HIE algorithm100.10,300.10and the alert algorithm100.50,300.50are performed, the IHU100.2.4uses the telemetry module100.2.4.14,300.2.4.14to wirelessly transmit impact information to the receiving unit100.2.6,300.2.6via communication links100.2.5,300.2.5. Specifically, the communication link100.2.5,300.2.5may be based on any type of wireless communication technologies. These wireless communication technologies may operate in an unlicensed band (e.g., 433.05 MHz-434.79 MHz, 902 MHz-928 MHz, 2.4 GHz-2.5 GHz, 5.725 GHz-5.875 GHz) or in a licensed band. A few examples of wireless communication technologies that that may be used, including but not limited to, Bluetooth, ZigBee, Wi-Fi (e.g., 802.11a, b, g, n), Wi-Fi Max (e.g., 802.16e), Digital Enhanced Cordless Telecommunications (DECT), cellular communication technologies (e.g., CDMA-1X, UMTS/HSDPA, GSM/GPRS, TDMA/EDGE, EV/DO, or LTE), near field communication (NFC), or a custom designed wireless communication technology. In other embodiments that are not shown, the telemetry module100.2.4.14,300.2.4.14may include both wired and wireless communication technologies. A few examples of wired communication technologies that may be used, include but are not limited to, any USB based communications link, Ethernet (e.g., 802.3), FireWire, or any other type of packet based wired communication technology.

As shown inFIG. 4, the receiving device100.2.6,300.2.6includes a telemetry module (not shown) that is configured to communicate with the telemetry module100.2.4.14,300.2.4.14to enable the impact information that is generated by the HIE algorithm100.10,300.10and the alert algorithm100.50,300.50to be transferred to the receiving device100.2.6,300.2.6. To enable this communication, the telemetry module contained within the receiving device100.2.6,300.2.6may utilize any of the above technologies that are described in connection with the telemetry module100.2.4.14,300.2.4.14. Once the impact information is received by the receiving device100.2.6,300.2.6, it can process this information to display relevant data to sideline personnel (e.g., trainer). This relevant data may include: (i) the impact value (e.g., graphical or non-graphical display of the magnitude of the impact), (ii) impact location (e.g., graphical or non-graphical), (iii) impact time, (iv) impact direction (e.g., graphical or non-graphical), (v) player's unique identifier (e.g., name or jersey number), (vi) alert type, (vii) player's heart rate, (viii) player's temperature, (ix) impact magnitude from the impact matrix, and/or (x) other relevant information. It should be understood that the receiving device100.2.6,300.2.6may be a portable hand-held unit that is typically carried by a person that is: (i) positioned proximate (e.g., within50yards) to the field or location that the physical activity is taking place and (ii) is not engaged in the physical activity (e.g., sideline personnel, which may be a trainer). Non-limiting examples of receiving devices100.2.6,300.2.6include: PDAs, cellular phones, watches, tablets, or custom designed alert units100.2.6.2,300.2.6.2.

Referring toFIG. 4, once the impact information has been received by the receiving device100.2.6,300.2.6, the impact information may be communicated via link100.2.7,300.2.7to the remote terminal100.2.8,300.2.8for additional analysis. This communication link100.2.7,300.2.7between the receiving device100.2.6,300.2.6and remote terminal100.2.8,300.2.8may be wireless or wired and may utilize any of the above described technologies. The remote terminal100.2.6,300.2.6is typically not proximate to the field, nor is it carried by a trainer during the activity. Instead, the remote terminal100.2.6,300.2.6is typically left in a secured location that is accessible shortly after the activity has been completed. Once the impact information is transferred from the receiving device100.2.6,300.2.6to the remote terminal100.2.8,300.2.8, the remote terminal100.2.8,100.2.8can upload the information to the team database100.2.10,300.2.10via communications link100.2.9,300.2.9or national database100.2.12,300.2.12via communications link100.2.14,300.2.14. The team database100.2.10,300.2.10is utilized to store information that is relevant to the team. In addition to the impact information, this relevant information may include: (i) practice calendars/schedules, (ii) equipment assignments and profiles (e.g., relevant sizes, type of shoes, type of helmet, type of energy attenuation assembly, type of chin strap, type of faceguard, and etc.), (iii) medical data for each player (e.g., medical histories, injuries, height, weight, emergency information, and etc.), (iv) statistics for each player (e.g., weight lifting records, 40 yard dash times, and etc.), (v) workout regiments for each player, (vi) information about the shape of the players body parts (e.g., head), and (vii) other player data (e.g., contact information).

The national database100.2.12,300.2.12stores all the information or a subset of the data that is stored in each of the team databases100.2.10,300.2.10around the nation or world. Specifically, the team databases100.2.10,300.2.10upload a copy of the information to the national database100.2.12,300.2.12via communications link100.2.13,300.2.13after a predefined amount of time has passed since the team database100.2.10,300.2.10was last uploaded to the national database100.2.12,300.2.12. Additionally, after the new data from the team database100.2.10,300.2.10is uploaded to the national database100.2.12,300.2.12, the team database100.2.10,300.2.10may download new thresholds from the national database100.2.12,300.2.12via communications link100.2.14,300.2.14. The data that may be contained within the national database100.2.12,300.2.12may include, but is not limited to: (i) single and cumulative alerts for each player across the nation/world, (ii) impact matrix for each player across the nation/world, (iii) other data related to the recorded physiological parameters for each player across the nation/world, (iv) equipment assignments and profiles of each player across the nation/world (e.g., relevant sizes, type of shoes, type of helmet, type of energy attenuation assembly, type of chin strap, type of faceguard, and etc.), (v) medical data for each player across the nation/world (e.g., medical histories, injuries, height, weight, emergency information, and etc.), (vi) statistics for each player across the nation/world (e.g., weight lifting records, 40 yard dash times, and etc.), (vii) workout regiments for each player across the nation/world, (viii) information about the shape of the players body parts (e.g., head), and (ix) other player data across the nation/world (e.g., contact information). It should also be understood that the national database100.2.12,300.2.12contains data that has been collected over many years and it includes at least the data collected using the proprietary technologies owned by the assignee of the present application, which is disclosed in U.S. Pat. Nos. 10,105,076, 9,622,661, 8,797,165, and 8,548,768, each of which is fully incorporated by reference herein. For example, this national database100.2.12,300.2.12currently includes data related to nearly six million impacts. WhileFIG. 4shows that the remote terminal100.2.8,100.2.8is separate from: (i) receiving device100.2.6,300.2.6, (ii) team database100.2.10,300.2.10, and (iii) a national database100.2.12,300.2.12, it should be understood that in an alternative embodiment these may all be combined together or partially combined together.

2. Collecting Shape Information

In addition to impact information, it may be desirable to collect information about the shape of player's heads to aid in designing the protective sports helmet1000. Referring toFIG. 1, steps110,210describe the acquisition of information about the shape of a player's body part (e.g., head). An exemplary method of collecting this shape information is described withinFIGS. 6A-6B. This method commences in step110.2,210.2by opening a software application110.4.4,210.4.4(exemplary embodiment shown inFIG. 9) in step110.4,210.4on, or in communication with, a scanning apparatus110.4.2,210.4.2(exemplary embodiment shown inFIGS. 7, 9 and 11). Referring back toFIG. 6A, upon opening the software application110.4.4,210.4.4, the operator is prompted in step110.6,210.6to select a player from a list of players or enter information about the player (e.g., name, age, playing level, position, etc.).

After the player information is entered in step110.6,210.6, the software application110.4.4,210.4.4prompts the operator to instruct and then check that the player P has properly placed the scanning hood110.8.2,210.8.2(exemplary embodiment shown inFIG. 7) on, or over, the head H of the player P in step110.8,210.8. The scanning hood110.8.2,210.8.2may be a flexible apparatus sized to fit over the player's head H and achieve a tight or snug fit around the player's head H due to elastic properties and dimensions of the scanning hood110.8.2,210.8.2, as can be seen inFIG. 7. The scanning hood110.8.2,210.8.2provides for increased accuracy when performing the information acquisition process by conforming to the anatomical features of the player's head H and facial region F, namely the topography and contours of the head H and facial region F while reducing effects of hair. The scanning hood110.8.2,210.8.2may be made from neoprene, lycra or any other suitable elastic material known to those skilled in the art. It should be understood that the term scanning hood110.8.2,210.8.2does not just refer to a hood that is placed over the head H of the player P; instead, it refers to a snug fitting item (e.g., shirt, armband, leg band, or etc.) that has minimal thickness and is placed in direct contact with the player's body part in order to aid in the collection of shape information.

As shown inFIGS. 7-8, one or more reference markers110.8.2.2.2,210.8.2.2.2may be placed on the scanning hood110.8.2,210.8.2. The reference markers110.8.2.2.2,210.8.2.2.2may be used to aid in the orientation and positioning of the images or video of the scanning hood110.8.2,210.8.2, as will be described below. The reference markers110.8.2.2.2,210.8.2.2.2may be: (i) colored, (ii) offset (e.g., raised or depressed) from other portions of the scanning hood110.8.2,210.8.2, (iii) include patterns or textures, (iv) or include electronic properties or features that aid in collection the of shape information by the scanning apparatus110.4.2,210.4.2. These reference markers110.8.2.2.2,210.8.2.2.2may be printed on the scanning hood110.8.2,210.8.2or maybe a separate item that is attached to the scanning hood110.8.2,210.8.2using adhesives or using any other mechanical or chemical attachment means. The number of reference markers110.8.2.2.2,210.8.2.2.2that are used should balance the need for an accurate collection of shape information on one hand with processing times on the other hand. In one exemplary embodiment, twelve reference markers110.8.2.2.2,210.8.2.2.2per square inch may be used. A person skilled in the art recognizes that more or fewer reference markers110.8.2.2.2,210.8.2.2.2may be used to alter the processing times and the accuracy of the shape information. In a further embodiment, it should be understood that the scanning hood110.8.2,210.8.2may not have any reference markers110.8.2.2.2,210.8.2.2.2.

In alternative embodiments, a scanning hood110.8.2,210.8.2may not be used when collecting shape information in certain situations. For example, scanning hood110.8.2,210.8.2may not be needed to reduce the effects of hair when capturing shape information about a player's foot, arm, or torso. In embodiments where a scanning hood110.8.2,210.8.2is not used, then one or more reference markers110.8.2.2.2,210.8.2.2.2may be directly placed on the player's body part. For example, the one or more reference markers110.8.2.2.2,210.8.2.2.2may have a removable coupling means (e.g., adhesive) that allows them to be removably coupled to the player's body part to aid in the collection of the shape information.

Referring toFIG. 6A, after the player P and/or the operator determines that the scanning hood502is properly positioned on the player's head H in step110.8,210.8, the operator is prompted to start the information acquisition process in step110.10,201,10. The information acquisition process may require different steps depending on the configuration of the scanning apparatus110.4.2,210.4.2and the technology that is utilized by the scanning apparatus110.4.2,210.4.2. In one exemplary embodiment, the scanning apparatus110.4.2,210.4.2may be a hand-held unit (e.g., personal computer, tablet or cellphone) that includes a non-contact camera based scanner. In this embodiment, the operator will walk around the player with the scanning apparatus110.4.2,210.4.2to collect images or video frames of the player. The scanning apparatus110.4.2,210.4.2or a separate device will be used to process the acquired shape information using photogrammetry techniques and/or algorithms. It should be understood that the shape information may be stored, manipulated, altered, and displayed in multiple formats, including numerical values contained within a table, points arranged in 3D space, partial surfaces, or complete surfaces.

In an alternative embodiment, the scanning apparatus110.4.2,210.4.2may be a hand-held unit (e.g., personal computer, tablet or cellphone) that includes a non-contact LiDAR or time-of-flight sensor. In this embodiment, the operator will walk around the player with the non-contact LiDAR or time-of-flight sensor. In particular, the LiDAR or time-of-flight sensor sends and receives light pulses in order to create a point cloud that contains shape information. In an alternative embodiment that is not shown, the scanning apparatus110.4.2,210.4.2may be a stationary unit that contains a non-contact light or sound based scanner (e.g., camera, LiDAR, etc.). In this embodiment, the light/sound sensors can capture the shape information in a single instant (e.g., multiple cameras positioned around the person that can all operate at the same time) or light/sound sensors may capture the shape information over a predefined period of time by the stationary unit's ability to move its sensors around the player P. In an even further embodiment that is not shown, the scanning apparatus may be a stationary contact based scanner assembly. In this embodiment, once the contact sensors are placed in contact with the player's body part, they can capture the shape information in a single instant (e.g., multiple pressure sensors may be positioned in contact with the player's body part to enable the collection of the shape information at one time). In another embodiment, the scanning apparatus may be a non-stationary contact based scanner. In this embodiment, the scanning apparatus may include at least one pressure sensor may capture the shape information over a predefined period of time by moving the pressure sensor over the player's body part. In other embodiments, shape information may be collected using: (i) computed tomography or magnetic resonance imaging, (ii) structured-light scanner, (iii) triangulation based scanner, (iv) conoscopic based scanner, (v) modulated-light scanner, (vi) any combination of the above techniques and/or technologies, or (vii) any technology or system that is configured to capture shape information. For example, the hand-held scanner may utilize both a camera and a time-of-flight sensor to collect the shape information.

FIG. 10shows an electronic device10, which is displaying an exemplary path that the scanning apparatus110.4.2,210.4.2may follow during the acquisition of shape information. The electronic device10is a computerized device that has an input device12and a display device14. The electronic device10may be a generic computer or maybe a specialized computer that is specifically designed to perform the computations necessary to carry out the processes that are disclosed herein. It should be understood that the electronic device10may not be contained within a single location and instead may be located at a plurality of locations. For example, the computing extent of the electronic device may be in a cloud server, while the display14and input device12are located in the office of the designer and can be accessed via an internet connection.

Referring back toFIG. 10, the hand-held scanning apparatus110.4.2,210.4.2is shown in approximately 40 different locations around a player's head H. These approximately 40 different positions are at different angles and elevations when compared to one another. Placing the scanning apparatus110.4.2,210.4.2in these different locations during the acquisition of shape information helps ensure that the information that will later be made from this acquisition process does not have gaps or holes contained therein. It should be understood that the discrete locations are shown inFIG. 10are exemplary and are simply included herein to illustrate the path that the scanning apparatus110.4.2,210.4.2may follow during the acquisition of shape information. There is no requirement that the scanning apparatus110.4.2,210.4.2pass through these points or pause to gather shape information at these points during the acquisition process.

Referring back toFIG. 6A, during the acquisition of shape information, the software application110.4.4,210.4.4may instruct the operator to: (i) change the speed at which they are moving around the player (e.g., slow down the pace) to ensure that the proper level of detail is captured in step110.12,210.12, (ii) change the vertical position and/or angle of the scanning apparatus110.4.2,210.4.2in step110.14,210.14, and/or (iii) change the operators position in relation to the player P (e.g., move forward or back up from the player) in step110.14,210.14. Once the acquisition of shape information is completed, the software application110.4.4,210.4.4analyzes the information to determine if the quality is sufficient to meet the quality requirements that are preprogrammed within the software application110.4.4,210.4.4. If the quality of the shape information is determined to be sufficient in step110.18, the software application110.4.4,210.4.4asks the operator if a helmet scan is desired. An example of where a helmet scan may be useful is when the player P desires a unique helmet configuration, such as if the player decides to have the helmet1000positioned lower on their head then where a wearer traditionally places the helmet1000. If it is determined that a helmet scan is desired in step110.30,210.30, then the operator will start the next stage of the acquiring shape information. The process of acquiring the helmet scan is described in connection withFIG. 6B. If it is determined that a helmet scan is not desired in step110.18,210.18, then the software application110.4.4,210.4.4will send, via a wire or wirelessly, to a local or remote computer/database (e.g., team database100.2.10,300.2.10), the shape information in step110.32,210.32. This local or remote computer/database may then be locally or remotely accessed by technicians/designers who perform the next steps in designing and manufacturing the helmet1000.

Alternatively, if the software application110.4.4,210.4.4determines that the shape information lacks sufficient quality to meet the quality requirements that are preprogrammed within the software application110.4.4,210.4.4, then the software application110.4.4,210.4.4may prompt the operator to obtain additional information in steps110.24,210.24,110.26,210.26. Specifically, in steps110.24,210.24, the software application110.4.4,210.4.4may graphically show the operator: (i) the location to stand, (ii) what elevation to place the scanning apparatus110.4.2,210.4.2, and/or (iii) what angle to place the scanning apparatus110.4.2,210.4.2. Once the operator obtains the additional information at that specific location, the software application110.4.4,210.4.4then analyzes the original collection of information along with this additional information to determine if the quality of the combined collection of information is sufficient to meet the quality requirements that are preprogrammed within the software application110.4.4,210.4.4. This process is then repeated until the quality of the information is sufficient. Alternatively, the software application110.4.4,210.4.4may request that the operator restart the shape information acquisition process. The software application110.4.4,210.4.4then analyzes the first collection of shape information along with the second collection of shape information to see if the combination of information is sufficient to meet the quality requirements that are preprogrammed within the software application110.4.4,210.4.4. This process is then repeated until the quality of the information is sufficient. After the shape information is determined to be sufficient, the software application110.4.4,210.4.4performs the step110.30,210.30of prompting the operator to determine if a helmet scan is desired.

FIG. 6Bdescribes the acquisition of additional shape information using a scanning helmet110.36.2,210.36.2. The first step in this process is110.36,210.36, which is accomplished by identifying the proper scanning helmet110.36.2,210.36.2. As an example for a player P, the scanning helmet110.36.2,210.36.2shell sizes may include medium, large and extra-large, although additional or intermediate sizes are certainly within the scope of this disclosure. The selection of the scanning helmet110.36.2,210.36.2shell size may be determined by the position the player plays, previous player experiences, or by estimations or measurements taken during or before the acquisition of the shape information. It should be understood that the term scanning helmet110.36.2,210.36.2does not just refer to a helmet that is placed over the player's head; instead, it refers to a modified version of the end product that is being designed and manufactured according to the methods disclosed herein, which aids in the collection of additional shape information.

Once the size of the scanning helmet110.36.2,210.36.2is selected in step110.36,210.36, the scanning helmet110.36.2,210.36.2is placed over the player's head H while the player P is wearing the scanning hood110.8.2,210.8.2in step110.40,210.40. After the scanning helmet110.36.2,210.36.2is placed on the player's head H in step110.40,210.40, the player adjusts the scanning helmet110.36.2,210.36.2to a preferred wearing position or configuration, which includes adjusting the chin strap assembly by tightening or loosening it. It is not uncommon for a player P to repeatedly adjust the scanning helmet110.36.2,210.36.2to attain his or her preferred wearing position because this position is a matter of personal preference. For example, some players prefer to wear their helmet lower on their head H with respect to their brow line, while other players prefer to wear their helmet higher on their head H with respect to their brow line.

As shown inFIG. 11, the scanning helmet110.36.2,210.36.2includes the chin strap110.36.2.1,210.36.1, one or more apertures110.36.2.2,210.36.2formed in a shell110.36.2.3,210.36.3of the helmet110.36.2,210.36.2and an internal scanning energy attenuation assembly110.36.2.4,210.36.4. The position, number, and shape of the apertures110.36.2.2,210.36.2.2in the scanning helmet110.36.2,210.36.2are not limited by this disclosure. For example, the scanning helmet110.36.2,210.36.2may have one aperture110.36.2.2,210.36.2.2that is smaller than the aperture110.36.2.2,210.36.2.2shown inFIG. 11, the scanning helmet110.36.2,210.36.2may have twenty apertures that are positioned in various locations throughout the shell, or the scanning helmet110.36.2,210.36.2may have three apertures. These apertures110.36.2.2,210.36.2allow certain portions of the scanning hood110.8.2,210.8.2to be seen when the scanning helmet110.36.2,210.36.2is worn over the scanning hood110.8.2,210.8.2on the player's head H. As mentioned above, the scanning helmet110.36.2,210.36.2includes the faceguard that is removably attached to a forward portion of the scanning helmet110.36.2,210.36.2. The faceguard may be used by the player, when wearing the scanning helmet110.36.2,210.36.2, to assist the player in determining a preferred helmet wearing position. Once the player positions the scanning helmet110.36.2,210.36.2such that a preferred helmet wearing position is achieved, the faceguard is removed to increase the accuracy of the helmet scan by allowing a scanning apparatus110.4.2,210.4.2to capture a greater, and less obscured, a portion of the player's face. To aid in the attachment and removal of the faceguard, easy to open and close clips may be utilized. Although the faceguard is removed, the chin strap assembly remains secured around the player's chin and jaw thereby securing the scanning helmet110.36.2,210.36.2in the preferred helmet wearing position.

Referring back toFIG. 6B, after the scanning helmet110.36.2,210.36.2is properly positioned on the player's head in steps110.42,210.42,110.44,210.42, the operator is prompted by the software application110.4.4,210.4.4to start the information acquisition process. Similar to the above process, the software application110.4.4,210.4.4may instruct the operator to: (i) change the speed at which they are moving around the player (e.g., slow down the pace) to ensure that the proper level of detail is captured in step110.48,210.48, (ii) change the vertical position and/or angle of the scanning apparatus110.4.2,210.4.2in step110.50,210.50, and/or (iii) change the operators position in relation to the player P (e.g., move forward or back up from the player) in step110.50,210.50. Once the operator completes the acquisition of additional shape information in step110.52,210.52, the software application110.4.4,210.4.4analyzes the information to determine if the quality of the information is sufficient to meet the quality requirements that are preprogrammed within the software application110.4.4,210.4.4in step110.54,210.54. If the software application110.4.4,210.4.4determines that the quality of the information is sufficient110.54,210.54, then the scanning apparatus110.4.2,210.4.2will send, via a wire or wirelessly, to a local or remote computer/database (e.g., team database100.2.10,300.2.10), the shape information. This local or remote computer/database may then be locally or remotely accessed by technicians who perform the next steps in designing and manufacturing the helmet1000.

Alternatively, if the software application110.4.4,210.4.4determines that the quality of the shape information lack sufficient quality to meet the quality requirements that are preprogrammed within the software application110.4.4,210.4.4, then the software application110.4.4,210.4.4may prompt the operator to obtain additional information in steps110.56,210.56,110.58,210.58. Specifically, in step110.56,210.56the software application110.4.4,210.4.4may graphically show the operator: (i) the location to stand, (ii) what elevation to place the scanning apparatus504, and/or (iii) what angle to place the scanning apparatus110.4.2,210.4.2. Once the operator obtains the additional shape information at that specific location, the software application110.4.4,210.4.4will then analyze the original collection of shape information along with this additional shape information to determine if the quality of the combined collection of shape information is sufficient to meet the quality requirements that are preprogrammed within the software application110.4.4,210.4.4. This process is then repeated until the quality of the information is sufficient. Alternatively, the software application110.4.4,210.4.4may request that the operator restart the information acquisition process in step110.58,210.58. The software application110.4.4,210.4.4then analyzes the first collection of shape information along with the second collection of shape information to see if the combination of information is sufficient to meet the quality requirements that are preprogrammed within the software application110.4.4,210.4.4. This process is then repeated until the quality of the information is sufficient. After the information is determined to be sufficient, the software application110.4.4,210.4.4performs step110.62,210.62. It should be understood that some of the steps in the process of acquiring shape information may be performed in a different order. For example, the acquisition of information in connection with the scanning hood110.8.2,210.8.2may be performed after the acquisition of information in connection with the scanning helmet110.36.2,210.36.2.

D. Create Specific Player Profile

The next step in this multi-step method 1 continues by creating the player's profile120.99,220.99,320.99. This player profile120.99,220.99,320.99may include impact information identified in step120.1,320.1, shape information identified in step120.50,320.50, both impact information and shape information identified in steps120.1,120.50,320.1,320.50, or some other combination of information about the player's attributes.

1. Impact Information for a Specific Player

The impact information for a specific player may be used to generate a complete impact matrix120.8.99,320.8.99or an impact score by the process described withinFIG. 12. This process starts by collecting impact information in step120.1,320.1. Referring toFIG. 13, the impact information may be collected from/using: (i)120.2.2,320.2.2, which is the system described above in connection withFIGS. 3A-3B, (ii)120.2.4,320.2.4, which is the Sideline Response System (SRS) that is disclosed in connection with U.S. Pat. Nos. 6,826,509; 7,526,389; 8,548,768; 8,554,509; 8,797,165; 9,622,661 and 10,292,650, all of which are fully incorporated herein by reference, (iii)120.2.6,320.2.6, which is the InSite Response System that is disclosed in connection with U.S. Pat. No. 10,105,076, which is fully incorporated herein by reference, and/or (iv)120.2.8,320.2.8, which are alternative systems (e.g., NFL's impact system).

Referring back toFIG. 12, once this impact information is collected in step120.1,320.1, the impact information may be used to generate a player impact matrix120.2.99,320.2.99in step120.2,320.2. Specifically, the impact matrix120.2.99,320.2.99may include 5 columns and 7 rows, where the 5 columns correspond to the location of the impact on the player's head (e.g., front, back, left, right, and top) and the 7 rows correspond to the severity of the impact (e.g., 1st, 2nd, 3rd, 4th, 5thseverity, single impact alert, or cumulative impact alert). An example120.2.75,320.2.75of such an impact matrix120.2.99,320.2.99is shown inFIG. 13. The impact information that may be used to create this matrix120.2.99,320.2.99may be compiled from all impacts or a subset of the impacts that have been received by a player. For example, a subset of the impacts may include impacts that are over: (i) the predetermined noise threshold, (ii) the 1stimpact threshold or impact matrix threshold, or (iii) the 2ndimpact threshold or high magnitude impact threshold. Additional information about this player impact matrix120.2.99,320.2.99is disclosed above and may be disclosed within U.S. Provisional Patent Application Ser. No. 62/778,559, which is hereby incorporated by reference.

Alternatively, the impact information may be used to generate a player impact score in step120.2,320.2. The impact information that may be used to create this impact score may be compiled from all impacts or a subset of the impacts that have been received by a player. For example, a subset of the impacts may include impacts that are over: (i) the predetermined noise threshold, (ii) the 1stimpact threshold or impact matrix threshold, or (iii) the 2ndimpact threshold or high magnitude impact threshold. Once the set of impact information is determined, the impact score may be calculated. Specifically, this impact score may be calculated by averaging the magnitudes of the impacts contained within the selected impact information. Alternatively, the impact score may be calculated by averaging the weighted magnitudes of each impact contained within the selected impact information, wherein the magnitudes are weighted by: (i) the location of the impact (e.g., side or back of the head has a greater weighting than the front of the head), (ii) frequency (e.g., ten impacts over a predefined threshold that were experienced over one hour has a greater weight than ten impacts over a predefined threshold over two weeks), (iii) number (e.g., an increasing multiplier is applied based on an increasing impact magnitude, which gives higher magnitude impacts greater weight), (iv) duration of the impact, (v) other head injury criteria values or calculations, (vi) player's specific attributes (e.g., position, weight, height, age, level), or (vii) a combination of these weighting methods.

Once the player's impact matrix120.2.99,320.2.99or impact score are generated within step120.2,320.2, the impact matrix120.2.99,320.2.99or impact score is reviewed to ensure that it is accurate and complete. If the data that is used to generate the impact matrix120.2.99,320.2.99or impact score is too incomplete (e.g., does not contain enough data to accurately calculate an impact matrix or impact score), then this impact matrix120.2.99,320.2.99or impact score is removed from this method 1 and further analysis in step120.4,320.4. Next, if other information (e.g., player's position or level), which is associated with the impact matrix or impact score is missing, then this impact matrix120.2.99,320.2.99or impact score is removed from this process and further analysis in step120.6,320.6. If the impact matrix120.2.99,320.2.99or impact score is removed for any reason, including the above reasons, then the system will try and obtain this information by searching the team database, sending an inquiry to the coach, sending an inquiry to the individual player, or trying to obtain this information from another source. Once this missing information is obtained, the helmet selection and/or design of the player's specific helmet may continue. If this information cannot be obtained, then certain protective sports helmets may not be available or the selected protective sports helmet may not be based on the player's impact information. Upon the completion of any one of the following steps120.6,320.6, the player's impact matrix/player's impact score120.8.99,320.8.99are outputted in steps120.8,220.8. These outputs form at least a portion of the player's profile120.99,320.99, which is uploaded to a database, local or remote, that can be accessed by technicians who perform the next steps in selecting, designing and/or manufacturing the helmet1000.

2. Shape Information for a Specific Player

The shape information for a specific player may be used to create a complete body part model120.70.99,220.70.99by the process described inFIG. 12. The process of creating this body part model120.70.99,220.70.99starts with collecting this information in step120.50,220.50. Referring toFIG. 14, this information may be generated and stored in connection with: (i)120.50.2,220.50.2, which is described above in connection withFIGS. 6A-6B, (ii)120.50.4,220.50.4, which are systems that are described within U.S. Pat. No. 10,159,296 and U.S. patent application Ser. No. 15/655,490 that are owned or licensed to the assignee of this application, or (iii)120.50.6,220.50.6, which is an alternative system. Referring back toFIG. 12, once the collection of player shape information120.50.99,220.50.99is identified, it is reviewed for its accuracy and completeness. First, the collection of player shape information is removed from this method 1 and further analysis, if it is incomplete (e.g., contains large holes) in step120.52,220.52. Next, in step120.54,220.54, the collection of player shape information is removed from this method 1 and further analyzed, if other information about the player (e.g., player's position or level) is missing. If the collection of player shape information is removed for any reason, including the above reasons, then the system will try and obtain this information by searching the team database, sending an inquiry to the coach, or sending an inquiry to the individual player. Once this missing information is obtained, this helmet selection and/or manufacturing may continue. If this information cannot be obtained, then certain protective sports helmets may not be available or the selected protective sports helmet may not be based on the player's shape information.

Next, a body part model120.58.99,220.58.99is created for the player based on the collected shape information120.50.99,220.50.99in step120.58,220.58. One method of creating the body part model120.58.99,220.58.99is using a photogrammetry based method. In particular, photogrammetry is a method that creates a model, preferably a 3D model, by electronically combining images or frames of a video. The electronic combination of these images or frames from a video may be accomplished in a number of different ways. For example, Sobel edge detection or Canny edge detection may be used to roughly find the edges of the object of interest (e.g., the scanning hood110.8.2,210.8.2or scanning helmet110.36.2,210.36.2). The computerized modeling system may then remove parts of each image or frame that are known not to contain the object of interest. This reduces the amount of data that will need to be processed by the computerized modeling system in the following steps. Additionally, removing parts of the images or frames, which are known not to contain the objects of interest reduces the chance of errors in the following steps, such as the correlating or matches of a reference point contained within the object of interest with the background of the image.

While still in step120.58,220.58, the computerized modeling system processes each image or frame of video to refine the detection of the edges or detect reference markers110.8.2.2.2,210.8.2.2.2. After refining the detection of the edges or detecting reference markers110.8.2.2.2,210.8.2.2.2, the computerized modeling system correlates or aligns the edges or reference markers110.8.2.2.2,210.8.2.2.2in each image to other edges or reference markers110.8.2.2.2,210.8.2.2.2in other images or frames. The computerized modeling system may use any one of the following techniques to align the images or frames with one another: (i) expectation-maximization, (ii) iterative closest point analysis, (iii) iterative closest point variant, (iv) Procrustes alignment, (v) manifold alignment, (vi) alignment techniques discussed in Allen B, Curless B, Popovic Z. The space of human body shapes: reconstruction and parameterization from range scans. In: Proceedings of ACM SIGGRAPH 2003 or (vii) other known alignment techniques. This alignment informs the computerized modeling system of the position of each image or frame of video, which is utilized to reconstruct a body part model120.58.99,220.58.99based on the acquired shape information.

The body part model120.58.99,220.58.99may also be created by the computerized modeling system using the shape information that is obtained by the above described non-contact LiDAR or time-of-flight based scanner. In this example, the computerized modeling system will apply a smoothing algorithm to the points contained within the point cloud that was generated by the scanner. This smoothing algorithm will create a complete surface from the point cloud, which in turn will be the body part model120.58.99,220.58.99. Further, the body part model120.58.99,220.58.99may be created by the computerized modeling system using the collection of pressure measurements that were taken by the contact scanner. Specifically, each of the measurements will allow for the creation of points within space. These points can then be connected in a manner that is similar to how points of the point cloud were connected (e.g., using a smoothing algorithm). Like above, the computerized modeling system's application of the smoothing algorithm will create a complete surface, which in turn will be the body part model120.58.99,220.58.99. Alternatively, the body part model120.58.99,220.58.99may be created by the computerized modeling system based on the shape information that was gathered using any of the devices or methods that were discussed above.

Alternatively, a combination of the above described technologies/methods may be utilized to generate the body part model120.58.99,220.58.99. For example, the body part model120.58.99,220.58.99may be created using a photogrammetry method and additional information may be added to the model120.99,220.99based on a contact scanning method. In a further example, the body part model120.58.99,220.58.99may be created by the computerized modeling system based on the point cloud that is generated by the LiDAR sensor and additional information may be added to the body part model120.58.99,220.58.99using a photogrammetry technique. It should also be understood that the body part model120.58.99,220.58.99may be analyzed, displayed, manipulated, or altered in any format, including a non-graphical format (e.g., values contained within a spreadsheet) or a graphical format (e.g., 3D model in a CAD program). Typically, the 3D body part model120.58.99,220.58.99is shown by a thin shell that has an outer surface, in a wire-frame form (e.g., model in which adjacent points on a surface are connected by line segments), or as a solid object, all of which may be used by the system and method disclosed herein.

Once the body part model120.58.99,220.58.99is created, the computerized modeling system determines a scaling factor. This is possible because the size of the reference markers110.8.2.2.2,210.8.2.2.2or other objects (e.g., coin, ruler, etc.) within the images or frames are known and fixed. Thus, the computerized modeling system determines the scaling factor of the model by comparing the known size of the reference markers110.8.2.2.2,210.8.2.2.2to the size of the reference markers in the model120.99,220.99. Once this scaling factor is determined, the outermost surface of the body part model120.58.99,220.58.99closely represents the outermost surface of the player's body part along with the outermost surface of the scanning hood110.8.2,210.8.2. While the thickness of the scanning hood110.8.2,210.8.2is typically minimal, it may be desirable to subtract the thickness of the scanning hood110.8.2,210.8.2from the body part model120.58.99,220.58.99after the model is properly scaled to ensure that the body part model120.58.99,220.58.99closely represents the outermost surface of the player's body part. Alternatively, the thickness of the scanning hood110.8.2,210.8.2may not be subtracted from the body part model120.58.99,220.58.99.

Once the body part model120.58.99,220.58.99is created and scaled in step120.58,220.58, anthropometric landmarks120.60.2,220.60.2may be placed on known areas of the body part model120.58.99,220.58.99by the computerized modeling system in step120.60,220.60. Specifically,FIG. 15shows multiple views of an exemplary body part model120.58.99,220.58.99, which includes a preset number of anthropometric points120.60.2,220.60.2are positioned thereon. These anthropometric points120.60.2,220.60.2typically are placed at locations that can be identified across most body part model120.58.99,220.58.99. As shown inFIG. 15, the points120.60.2,220.60.2are positioned on the tip of the nose, edges of the eyes, between the eyes, the forwardmost edge of the chin, edges of the lips, and other locations. It should be understood that a body part model120.58.99,220.58.99may be a model of any body part of the player/helmet wearer, including a head, foot, elbow, torso, neck, and knee. The following disclosure focuses on the design and manufacture of a protective sports helmet1000that is designed to receive and protect a player's head. Thus, the body part model120.58.99,220.58.99discussed below in the next stages of the method is a model of the player's head or a “head model.” Nevertheless, it should be understood that the following discussion involving the head model in the multi-step method 1 is only an exemplary embodiment of the method 1 for the selection and/or design of a protective helmet1000, and this embodiment shall not be construed as limiting.

Referring back toFIG. 12, in step120.62,220.62, the head model120.99,220.99is registered or aligned in a specific location using the computerized system. This is done to ensure that the head model120.99,220.99is in a known position to enable the comparison between the player's head model120.99,220.99with: (i) body part models that were derived from other players, (ii) reference surfaces associated with stock energy attenuation assemblies, (iii) reference surfaces associated with stock helmets, or (iv) other relevant information. Specifically, this registration or alignment removes head rotations, alignment shifts, and sizing issues between the models120.99,220.99. This can be done in a number of ways, a few of which are discussed below. For example, one method of aligning the head models120.99,220.99may utilize a rotational based method on the placement of the anthropometric points120.60.2,220.60.2. This method is performed by first moving the entire head model to a new location, wherein in this new location one of the anthropometric points120.60.2,220.60.2positioned at a zero. Next, two rotations are performed along Z and Y axes so that the left and right tragions lie along the X-axis. Finally, the last rotation is carried out along the X-axis so that the left infraorbital lies on the XY-plane. This method will be repeated for each head model, helmet model, and helmet component model to ensure that relevant data is aligned in the same space.

An alternative method of aligning the relevant data (e.g., head models120.99,220.99and helmet models) may include aligning anthropometric points120.60.2,220.60.2that are positioned on the head models120.99,220.99with anthropometric points that are positioned on a generic head model. The alignment of the anthropometric points may be accomplished using any of the methods that are disclosed above (e.g., expectation-maximization, iterative closest point analysis, iterative closest point variant, Procrustes alignment, manifold alignment, and etc.) or methods that are known in the art. Another method of aligning the relevant data may include determining the center of the head model120.99,220.99and placing the center at 0, 0, 0. It should be understood that one or a combination of the above methods may be utilized to align or register the head models120.99,220.99with one another. Further, it should be understood that other alignment techniques that are known to one of skill in the art may also be used in aligning the head models120.99,220.99with one another. Such techniques include the techniques disclosed in all of the papers that are attached to U.S. Provisional Application No62/364,629, which are incorporated into the application by reference.

After the head model120.99,220.99is aligned and registered in space, the computerized modeling system may apply a smoothing algorithm to the head model120.58.99,220.58.99in step120.64,220.64. Specifically, the head model120.58.99,220.58.99may have noise that was introduced by movement of the player's head H while the shape information was obtained or a low resolution scanner was utilized. Exemplary smoothing algorithms that may be applied include: (i) interpolation function, (ii) the smoothing function described within Allen B, Curless B, Popovic Z.The space of human body shapes: reconstruction and parameterization from range scans. In: Proceedings of ACM SIGGRAPH 2003, or (iii) other smoothing algorithms that are known to one of skill in the art (e.g., the other methods described within the other papers are attached to or incorporated by reference in U.S. Provisional Patent Application No. 62/364,629, each of which is incorporated herein by reference).

If the system or designer determines that the head model120.58.99,220.58.99is too incomplete to only use a smoothing algorithm, the head model120.58.99,220.58.99may be overlaid on a generic model in step120.66,220.66. For example, utilizing this generic model fitting in comparison to attempting to use a smoothing algorithm is desirable when the head model120.58.99,220.58.99is missing a large part of the crown region of the player's head. To accomplish this generic model fitting, anthropometric landmarks120.60.2,220.60.2that were placed on the head model120.99,220.99are then aligned with the anthropometric landmarks120.60.2,220.60.2of the generic model using any of the alignment methods that are disclosed above (e.g., expectation-maximization, iterative closest point analysis, iterative closest point variant, Procrustes alignment, manifold alignment, and etc.) or methods that are known in the art. After the head model120.99,220.99and the generic model are aligned, the computerized modeling system creates gap fillers that are based upon the generic model. Similar gap filling technique is discussed within P. Xi, C. Shu,Consistent parameterization and statistical analysis of human head scans. The Visual Computer, 25 (9) (2009), pp. 863-871, which is incorporated herein by reference. It should be understood that a smoothing algorithm from step120.60,220.60may be utilized after gaps in the head model120.99,220.99are filled in step120.62,220.62. Additionally, it should be understood that the head model120.99,220.99may not require smoothing or filling; thus, steps120.64,220.64,120.66,220.66are skipped.

After the head models120.99,220.99are aligned or registered in step120.66,220.66and the surfaces of the head models120.99,220.99have been adjusted, surface data that is not relevant to the fitting of the helmet or non-fitting surface120.68.2,220.68.2may be removed from the head model120.99,220.99in step120.68,220.68. This step of removing the non-fitting surface area120.68.2,220.68.2may be accomplished in a number of different ways. For example, an algorithm can be utilized to estimate the non-fitting surface120.68.2,220.68.2and the fitting surface120.68.4,220.68.4. This algorithm may be based on: (i) commercial helmet coverage standards, such as the standards set forth by National Operating Committee on Standards for Athletic Equipment, (ii) the surface area that is covered by the scanning hood110.8.2,210.8.2, (iii) historical knowledge or (iv) other similar methods.FIGS. 16A-16Cshow exemplary embodiments of the fitting surface120.68.4,220.68.4and the non-fitting surface120.68.2,220.68.2. Once this fitting surface120.68.4,220.68.4is determined, then all non-fitting surfaces120.68.2,220.68.2may be removed from the head model120.99,220.99.

Alternatively, the non-fitting surfaces or irrelevant surfaces120.68.2,220.68.2may be removed from the head model120.99,220.99using the helmet scan. This may be accomplished by aligning the helmet scan with the head model120.99,220.99using any of the methods that are disclosed above (e.g., expectation-maximization, iterative closest point analysis, iterative closest point variant, Procrustes alignment, manifold alignment, and etc.) or other methods that are known in the art. For example, the helmet scan's reference markers110.8.2.2.2,210.8.2.2.2that are detected through the one or more apertures110.36.2.2,210.36.2formed in a shell110.36.2.3,210.36.3of the scanning helmet110.36.2,210.36.2may be aligned with the same reference markers110.8.2.2.2,210.8.2.2.2contained on the head model120.99,220.99. Alternatively, a player's anthropometric features (e.g., brow region, upper lip region, nose bridge or nose tip) that are contained within both the helmet scan and the head model120.99,220.99may be aligned. Once these alignment methods are utilized, a visual and/or manual inspection of the alignment across multiple axes can be performed by a human or computer software. Once the alignment of the helmet scan and the head model are confirmed, then the non-fitting surface120.68.2,220.68.2can be removed from the head model in step120.68,220.68.

In a further alternative, the non-fitting surfaces120.68.2,220.68.2may be removed from the head model120.99,220.99but the anthropometric landmarks120.60.2,220.60.2may not be removed, even if they are located within the regions of the non-fitting surfaces120.68.2,220.68.2. This may be desirable because these landmarks120.60.2,220.60.2may be used during later stages of this method 1 to ensure proper alignment between the head model120.99,220.99and digital helmets. In even a further alternative, the non-fitting surfaces120.68.2,220.68.2may not be removed from the head model120.99,220.99. These non-fitting surfaces120.68.2,220.68.2might not need to be removed because the scanning technology (e.g., contact scanner or pressure scanner) that was utilized only identifies fitting surfaces120.68.4,220.68.4. Additionally, the designer may desire not to these non-fitting surfaces120.68.2,220.68.2because they may aid in manipulation or alignment of the head model120.99,220.99during later stages of this method 1.

Upon the completion of any one of the following steps120.62,220.62,120.64,220.64,120.66,220.66,120.68,220.68, complete head model120.70.99,220.70.99are outputted in steps120.70,220.70. These outputs: (i) form at least a portion of the player's profile120.99,220.99and (ii) can be uploaded to a database, local or remote, that can be accessed by technicians who perform the next steps in selecting, designing and/or manufacturing the helmet1000. Additionally, the system may combine the complete head model120.70.99with the complete impact matrix/impact score120.8.99to create a player profile120.99, which includes both impact and shape information. Similar to what has been described above, this version of the player's profile120.99,220.99,320.99can be uploaded to a database, local or remote, that can be accessed by technicians who perform the next steps in selecting, designing and/or manufacturing the helmet1000.

It should be understood that the steps described within the method of preparing the information120,220,320may be performed in a different order. For example, the removal of information that is incomplete in steps120.4,320.4,120.52,220.52and removal of information that is missing other relevant info120.6,320.6,120.54,220.54may not be performed or may be performed at any time after steps120.2,320.2,120.50,220.50, respectfully. Further, it should be understood that the impact information may not be analyzed if the process of designing and manufacturing the helmet1000is focused on using only shape information. Likewise, it should be understood that the shape information may not be analyzed if the process of designing and manufacturing the helmet1000is focused on using only impact information.

E. Selection of a Stock Helmet or Stock Helmet Components

After the player's profile120.99,220.99,320.99has been created—namely: (i) the combination of a complete head model120.70.99and a complete impact matrix/score120.8.99, (ii) only the complete head model220.70.99, or (iii) only the complete impact matrix/score320.8.99, the player's profile120.99,220.99,320.99is compared to digital information170.2,270.2,370.2associated with stock helmets or stock helmet components to determine which stock helmet or stock helmet components best fit the player's profile120.99,220.99,320.99.

1. Importation of Information Associated with Stock Helmet or Stock Helmet Components

Referring toFIG. 17, digital information170.2(e.g., digital models of helmets, heads, impact matrixes/scores, or other parameters) about stock helmet or stock helmet components are imported into the system in step170.1,270.1,370.1, which were obtained from or derived from: (i) historical knowledge, (ii) public databases, (iii) organizational bodies (e.g., NFL, NCAA), (iv) research companies or institutions (e.g., Virginia Tech), or (v) the process disclosed within U.S. patent application Ser. No. 16/543,371. In one embodiment, the method 1 disclosed herein may import the complete stock helmet models170.4,270.4,370.4that were created within U.S. patent application Ser. No. 16/543,371. Generally, these complete stock helmet models170.4,270.4,370.4were created by selecting a group of players from a plurality of players and analyzing shape information and impact information, associated with the selected group, in order to generate a complete stock helmet model170.4,270.4,370.4. As discussed within U.S. patent application Ser. No. 16/543,371, the selection of a specific group of players may be based upon: (i) player position, (ii) player level, or (iii) a combination of player position and level. Here, an example of the complete stock helmet models170.4is shown inFIG. 18. In particular,FIG. 18shows the complete stock helmet model170.4and supporting information170.6(e.g., shape information170.6.2and impact information170.6.4) from which it was derived. In this exemplary embodiment, there are four complete stock helmet models170.4.2,170.4.4,170.4.6,170.4.8that can be denoted as a small size, medium size, large size, and extra-large size. Likewise, there are four collections of shape information170.6.2.2,170.6.2.4,170.6.2.6,170.6.2.8and four collections of impact information170.6.4.2,170.6.4.4,170.6.4.6,170.6.4.8. To better understand how the four collections of shape information170.6.2.2,170.6.2.4,170.6.2.6,170.6.2.8differ from one another,FIG. 19compares the outer surface170.6.2.1of these collections170.6.2.2,170.6.2.4,170.6.2.6,170.6.2.8. Overall, in this exemplary embodiment of cross-sectional views, it can be seen that the overall circumference shown in2-2does not change as much as the elevation in the crown of the head shown in1-1and3-3.

In addition to the supporting information170.6that is described above, each complete stock helmet model170.4,270.4,370.4includes reference surfaces170.20,270.20. An exemplary graphical embodiment of these reference surfaces170.20,270.20is shown inFIG. 20. One of the reference surfaces170.20that is shown inFIG. 20is a minimum certified surface (MCS)170.20.2. This MCS170.20.2is defined by a collection of minimum distance values170.20.2.2that extend inward from the inner surface170.30.2of the helmet shell170.30. When the complete stock helmet model170.4is properly placed on the complete head model120.70.99, the outer surface120.70.99.2of the complete head model120.70.99should not extend beyond the MCS170.20.2. As such, if the outer surface120.70.99.2of the complete head model120.70.99extends through the MCS170.20.2, then a larger helmet shell170.30needs to be selected and utilized for the player. Alternatively, if the outer surface120.70.99.2of the complete head model120.70.99does not extend through the MCS170.20.2, then the MCS170.20.2is satisfied and the selected helmet shell170.30can be utilized for the player. In other words, the MCS170.20.2is satisfied when the distance between the inner surface170.30.2of the helmet shell170.30and the outer surface120.70.99.2of the player's head is greater than or equal to the minimum distance values170.20.2.2for a particular shell size. It should be understood that satisfying the MCS170.20.2does not mean that the helmet is properly sized for the player's head. For example, a helmet that is too large for a player will not fit properly, but the MCS170.20.2will be satisfied. Thus, the MCS170.20.2is used to ensure that the player is not given too small of a helmet.

In addition to the MCS170.20.2, the complete stock helmet model170.4may include a maximum surface170.20.4. This maximum surface170.20.4is derived from analyzing the shape information that is associated with the selected group of players and may be included within the player group—shape based standard and/or player group—shape+impact based standard. See U.S. patent application Ser. No. 16/543,371. Like the MCS170.20.2, when the complete stock helmet model170.4is properly aligned with the complete head model120.70.99, using the techniques that are discussed above, the outer surface120.70.99.2of the complete head model120.70.99should not extend beyond the maximum surface170.20.4. As such, if the outer surface120.70.99.2of the complete head model120.70.99extends through or beyond the maximum surface170.20.4, then a larger helmet shell170.30is typically needed. In certain embodiments, the complete head model120.70.99may extend beyond the maximum surface170.20.4because the maximum surface170.20.4is only a suggested reference surface that is designed to help ensure that the pressure exerted by the energy attenuation assembly170.40on the player's head does not exceed the maximum pre-impact pressure (e.g., 10 psi). Alternatively, if the outer surface120.70.99.2of the complete head model120.70.99does not extend through the maximum surface170.20.4, then the maximum surface170.20.4is satisfied and the selected complete stock helmet model170.4can be utilized for the player. It should be understood that satisfying the maximum surface170.20.4does not mean that the helmet is properly sized for the player's head. For example, a helmet that is too large for a player will not fit properly, but the maximum surface170.20.4will be satisfied. In a non-limiting exemplary embodiment of the complete stock helmet model170.4.6, the maximum surface170.20.4may be inset approximately four millimeters from the inner surface of the energy attenuation assembly170.40.

In addition to the MCS170.20.2and the maximum surface170.20.4, the complete stock helmet model170.4may include a minimum surface170.20.6. This minimum surface170.20.6is derived from analyzing the shape information that is associated with the selected group of players and may be included within the player group—shape based standard and/or player group—shape+impact based standard. See U.S. patent application Ser. No. 16/543,371. Unlike the MCS170.20.2, when the complete stock helmet model170.4is properly aligned with the complete head model120.70.99, using the techniques that are discussed above, the outer surface120.70.99.2of the complete head model120.70.99should extend beyond the minimum surface170.20.6. As such, if the outer surface120.70.99.2of the complete head model120.70.99does not extend through the minimum surface170.20.6, then a smaller helmet shell170.30is typically needed. In certain embodiments, the complete head model120.70.99may not extend beyond the minimum surface170.20.6because the minimum surface170.20.6is only a suggested reference surface that is designed to help ensure that the pressure exerted by the energy attenuation assembly170.40on the player's head is not below a minimum pre-impact pressure (e.g., 1 psi). Alternatively, if the outer surface120.70.99.2of the complete head model120.70.99does extend through the minimum surface170.20.6, then the minimum surface170.20.6is satisfied and the selected complete stock helmet model170.4can be utilized for the player. In a non-limiting exemplary embodiment of the complete stock helmet model170.4.6, the minimum surface170.20.6may be inset approximately one millimeter from the inner surface of the energy attenuation assembly170.40.

While the reference surfaces170.20are only shown for one complete stock helmet model170.4, it should be understood that every complete stock helmet model170.4,270.4,370.4includes such reference surfaces170.20,270.20. Additionally, it should be understood that fewer reference surfaces170.20,270.20may be included in each complete stock helmet model170.4,270.4,370.4. For example, the complete stock helmet model170.4,270.4,370.4may only include the MCS170.20.2,270.20.2. Further, it should be understood that the complete stock helmet model170.4,270.4,370.4may include additional reference surfaces170.20,270.20. It should also be understood that while this example shows four complete stock helmets170.4,270.4,370.4, U.S. patent application Ser. No. 16/543,371 contemplates the inclusion of additional complete stock helmets170.4,270.4,370.4. For example, there may be 27 complete stock helmets170.4based upon the analysis of all players, 40 complete stock helmets170.4based on player position, 19 complete stock helmets170.4based on player level, and 46 complete stock helmets170.4based on both player position and level. Alternatively, there may be fewer than 4 complete stock helmets170.4or there may be more than 46 complete stock helmets170.4.

In an alternative embodiment, the method 1 disclosed herein may import the complete stock helmet models270.4that were created within U.S. patent application Ser. No. 16/543,371 based on the analysis of shape information for selected groups of players. These complete stock helmet models270.4in this embodiment do not account for impact information and thus do not include this information. Similar to the above disclosure, there may be 7 complete stock helmets270.4based upon the analysis of all players, 18 complete stock helmets270.4based on player position, 11 complete stock helmets270.4based on player level, and 24 complete stock helmets270.4based on both player position and level. Alternatively, there may be fewer than seven complete stock helmets270.4or there may be more than 24 complete stock helmets270.4. In another alternative embodiment, the method 1 disclosed herein may import the complete stock helmet models370.4that were created within U.S. patent application Ser. No. 16/543,371 based on the analysis of impact information for selected groups of players. These complete stock helmet models370.4in this embodiment do not account for shape information and thus do not include this information. Similar to the above disclosure, there may be 14 complete stock helmets370.4based upon the analysis of all players, 12 complete stock helmets370.4based on player position, 21 complete stock helmets370.4based on player level, and 35 complete stock helmets370.4based on both player position and level. Alternatively, there may be fewer than 14 complete stock helmets370.4or there may be more than 35 complete stock helmets370.4.

In a further embodiment, only correlations between stock helmet components may be imported. For example, helmet shells may be imported with MCS170.20.2.270.20.2, which may be used to inform the designer about the maximum player head size that the helmet shell can accommodate. Similarly, members of the energy attenuation assembly170.40,270.40,370.40may only include information about which shells they fit into, their thickness profile, playing level (e.g., youth, varsity, NCAA, NFL) that they are optimized for and/or playing positions (e.g., lineman, quarterback, receiver, running back, etc.) that they are optimized for. Overall, this embodiment does not include complete stock helmet models but instead individual stock helmet components.

In another embodiment, a hybrid between the complete stock helmet model170.4,270.4,370.4and the correlation between stock helmet components may be utilized. For example, complete stock helmet models170.4,270.4,370.4that are disclosed within U.S. patent application Ser. No. 16/543,371 may be imported along with a present number of different energy attenuation assemblies. This embodiment simplifies the selection of the stock helmet components and helps ensure the method 1 only provides results that are desirable. For example, if the method 1 is permitted to select each and every component based on a player's profile, then the method 1 may take too long to analyze all the combinations of helmet components or suggest some undesirable matches. Additionally, this hybrid approach helps ensure the method 1 can utilize a sufficient number of combinations of helmet components to best match the player's profile120.99,220.99,320.99.

2. Digital Selection of a Stock Helmet or Stock Helmet Components

Digital information170.2,270.2,370.2(e.g., digital models of helmets, heads, impact matrixes/scores, or other parameters) about the complete stock helmet models170.4,270.4,370.4or stock helmet components are imported into the system in step170.1,270.1,370.1. This imported information is compared to the player's profile120.99,220.99,320.99to determine which complete stock helmet models170.4,270.4,370.4or stock helmet components best fit the player's profile120.99,220.99,320.99in step170.50,270.50,370.50. This comparison and selection can be performed in multiple different ways depending on the digital information170.2,270.2,370.2that is imported into the system, as discussed below.

i. Selection of a Complete Stock Helmet Model from a Plurality of Complete Stock Helmet Models

Referring toFIG. 17, the complete stock helmet models170.4,270.4,370.4that best matches the player may be selected based upon: (i) the player's profile120.99, which contains the player's complete head model120.70.99and the player's complete impact matrix/score120.8.99, (ii) the player's profile220.99, which contains only the player's complete head model220.70.99, or (iii) the player's profile320.99, which contains only the player's complete impact matrix/score320.8.99. As shown inFIG. 1, once the complete stock helmet models170.4,270.4,370.4or stock helmet components are chosen in steps170,270,370, the parts that correspond to these models may be shipped to the player in step199A,299A,399A.

1. Selection Based on the Player's Head Model and Impact Matrix/Score

Referring toFIG. 21, the process170.60.2of selecting the complete stock helmet170.4that best matches the player's profile120.99starts by importing and confirming that the player's profile120.99contains the player's complete head model120.70.99and the player's complete impact matrix/score120.8.99in step170.60.2.2. After this data is imported and confirmed in step170.60.2.2, then the designer inputs a predetermined distance170.60.2.4.2in step170.60.2.4, which is utilized to modify an outer surface120.70.99.2of the complete head model120.70.99. A graphical example of this modification is shown inFIG. 24, where the outer surface120.70.99.2of the complete head model120.70.99is moved inward a predetermined distance170.60.2.4.2to form the inset modified surface120.70.99.4. In other words, the designer created the modified surface120.70.99.2by “insetting” or moving inward the outer surface120.70.99.2a predetermined distance170.60.2.4.2, where this inset provides appreciable benefits, including creating an interference fit between the player's head (i.e., outer surface120.70.99.2of the complete head model120.70.99) and the inner surface170.40.2of the energy attenuation assembly170.40. It should be understood that the predetermined distance170.60.2.4.2may be: (i) a positive value, which insets the outer surface, (ii) zero, which does not alter the outer surface, or (iii) a negative value, which expands the outer surface.

Referring back toFIG. 21, the next step in selecting the complete stock helmet170.4is to compare the outer surface120.70.99.2of the complete head model120.70.99against the MCS170.20.2for each of the complete stock helmets170.4that were previously created and contained within the database in step170.60.2.8. See U.S. patent application Ser. No. 16/543,371. As discussed above, the MCS170.20.2is satisfied when the outer surface120.70.99.2does not extend through the MCS170.20.2. If the MCS170.20.2that is associated with a complete stock helmet170.4is not satisfied in step170.60.2.8, then that complete stock helmet170.4is removed from further analysis in step170.60.2.10. Three graphical examples of complete stock helmets170.4are shown inFIGS. 25-27and are compared against the outer surface120.70.99.2of the complete head model120.70.99. In particular,FIG. 25shows a graphical image of a large size complete stock helmet170.4.6, whileFIG. 26shows a graphical image of a small size complete stock helmet170.4.2andFIG. 27shows a graphical image of a medium size complete stock helmet170.4.4. As shown inFIG. 26, the MCS170.20.2.2is not satisfied because the outer surface120.70.99.2.2of the complete head model120.70.99extends through or beyond the MCS170.20.2.2. In other words, a small size complete stock helmet170.4.2is too small for the player based on the size of the player's head. Alternatively, if the MCS170.20.2that is associated with a complete stock helmet170.4is satisfied in step170.60.2.8, then that complete stock helmet170.4remains available for selection in step170.60.2.12. As shown inFIGS. 25 and 27, the MCS170.20.2.6,170.20.2.4is satisfied because the outer surface120.70.99.2,120.70.99.2of the complete head model120.70.99,120.70.99does not extend through the MCS170.20.2.6,170.20.2.4. In other words, the large size complete stock helmet170.4.6and the medium size complete stock helmet170.4.4may fit the player. This being said, additional steps will be performed to ensure that the complete stock helmet170.4that best fits the player's profile120.99is chosen.

Next, in step170.60.2.14, the outer surface120.70.99.2of the complete head model120.70.99is compared against the maximum surface170.20.4for each of the complete stock helmets170.4that remained available for selection in step170.60.2.12. As discussed above, the maximum surface170.20.4is satisfied when the outer surface120.70.99.2does not extend through the maximum surface170.20.4. If the maximum surface170.20.4that is associated with a complete stock helmet170.4is not satisfied in step170.60.2.14, then that complete stock helmet170.4is removed from further analysis in step170.60.2.16. Although the complete stock helmet170.4.2shown inFIG. 26, was previously removed from analysis in step170.60.2.10due to the fact that the MCS170.20.2.2was not satisfied, this complete stock helmet170.4.2would also be removed in step170.60.2.16because maximum surface170.20.4.2is not satisfied. As described above, the small size complete stock helmet170.4.2is too small for the player based on the size of the player's head. Alternatively, if the maximum surface170.20.4that is associated with a complete stock helmet170.4is satisfied in step170.60.2.14, then that complete stock helmet170.4remains available for selection in step170.60.2.18. Graphical examples of the maximum surface170.20.4.6,170.20.4.4that is satisfied is shown inFIGS. 25 and 27. As discussed above, the maximum surface170.20.4.6,170.20.4.4is satisfied because the outer surface120.70.99.2of the complete head model120.70.99does not extend through or beyond the maximum surface170.20.4.6,170.20.4.4. Also, as described above, the large size complete stock helmet170.4.6and the medium size complete stock helmet170.4.4may fit the player. This being said, additional steps will be performed to ensure that the complete stock helmet170.4that best fits the player's profile120.99is chosen.

Next, in step170.60.2.20, the outer surface120.70.99.2of the complete head model120.70.99is compared against the minimum surface170.20.6for each of the complete stock helmets170.4that remain available for selection in step170.60.2.18. As discussed above, the minimum surface170.20.6is satisfied when the outer surface120.70.99.2extends through or beyond the minimum surface170.20.6. If the minimum surface170.20.6that is associated with a complete stock helmet170.4is not satisfied in step170.60.2.20, then that complete stock helmet170.4is removed from further analysis in step170.60.2.22. A graphical example of the minimum surface170.20.6.6that is not satisfied is shown inFIG. 25because the outer surface120.70.99.2of the complete head model120.70.99does not extend through the minimum surface170.20.6.6. In other words, the large size complete stock helmet170.4.6is too large for the player based on the size of the player's head. Alternatively, if the minimum surface170.20.6that is associated with a complete stock helmet170.4is satisfied in step170.60.2.20, then that complete stock helmet170.4remains available for selection in step170.60.2.24. Graphical examples of the minimum surface170.20.6.2,170.20.6.4that are satisfied are shown inFIGS. 26-27. As discussed above, the minimum surface170.20.6.2,170.20.6.4are satisfied because the outer surface120.70.99.2of the complete head model120.70.99extends through the minimum surface170.20.6.2,170.20.6.4. In other words, complete stock helmets170.4.2,170.4are small enough to ensure that the player's head will make at least the minimum amount of contact with the energy attenuation assembly2000,3000, when the player places the helmet on their head.

Based on the above analysis, the only graphical representation of the complete stock helmet models170.4that passes each of these tests is shown inFIG. 27. In other words, the complete stock helmet model170.4.4shown inFIG. 27satisfies: (i) the MCS170.20.2.4and the maximum surface170.20.4.4because outer surface120.70.99.2of the complete head model120.70.99does not extend through or beyond these surfaces170.20.2.4,170.20.4.4and (ii) the minimum surface170.20.6.4because outer surface120.70.99.2of the complete head model120.70.99does extend through this surface170.20.6.4. Because the complete stock helmet model170.4.4passes each of the above tests, this complete stock helmet model170.4.4will pass on to the analysis contained withinFIG. 22in step170.60.2.24.

Depending on how the complete stock helmet models170.4were generated, there may only be one complete stock helmet model170.4that fits the player or there may be multiple complete stock helmet models170.4that fit the player. As shown in170.60.2.26, a single complete stock helmet model170.4will be identified because the complete stock helmet models170.4were created based upon all players. In other words, the players were not split-up into groups based on attributes, such as position, level, or position and level. In this situation, the system does not need to analyze the player's impact matrix/score120.8.99,320.8.99because this analysis will not impact the selection of the complete stock helmet model170.4due to the fact that the complete stock helmet model170.4was not created to differentiate between players that have different impact matrixes/scores.

Alternatively, as shown in170.60.2.28-170.60.2.32, multiple complete stock helmet models170.4were identified because the complete stock helmet models170.4were created after sorting the players based upon specific attributes, such as position, level, or position and level. In this situation, the system performs step170.60.2.34, which compares the player's impact matrix/score120.8.99,320.8.99to the impact matrix/scores170.6.4that are associated with the complete stock helmet models170.4that are still available for analysis. Based on this comparison and the protective sports helmet that the player selected in the steps associated with step50, the system recommends one of the identified complete stock helmet models170.4in step17.60.2.36. In other words, this process compared the player's complete head model120.70.99with different sized complete stock helmet models170.4to determine the size of the complete stock helmet model170.4that best fits the player. After the best fitting complete stock helmet models170.4where identified, then the player's impact matrix/score120.8.99was compared with the impact matrix/score of each of the best fitting complete stock helmet models170.4. Based on this comparison and the player's protective sports helmet selections in step50, the system recommended the complete stock helmet model that best matched the shape of the player's head and impacts that the player receives while engaged in playing the sport in step17.60.2.36.

It should be understood that the above analysis will attempt to suggest a complete stock helmet model170.4that was derived from: (i) only player's that play at a similar level to the player, (ii) only player's that play a similar position to the player, or (iii) only player's that play a similar position and a similar level to the player. However, it should be understood that the above analysis may suggest complete stock helmet models170.4that are derived from: (i) player's that play at a level that is different than the player, (ii) player's that play a position that is different than the player, or (iii) player's that play a position and at a level that is different than the player. For example, based on the player's profile120.99, the system may recommend that a player that typically plays running back at the varsity level should wear a helmet that is designed for wide receivers that play at the NCAA level. Additionally, based on the player's profile120.99, the system may recommend that a player that typically plays tight end at the NCAA level should wear a helmet that is designed for lineman that play at the NCAA level. Further, based on the player's profile120.99, the system may recommend that a quarterback that plays at the NCAA level should wear a helmet that is designed for a quarterback that plays at the varsity level. Moreover, based on the player's profile120.99, the system may recommend that a wide receiver that plays at the youth level should wear a helmet that is designed for a wide receiver that plays at the varsity level. Finally, based on the player's profile120.99, the system may recommend that a lineman that plays at the NCAA level should wear a helmet that is designed for a lineman that plays at the NCAA level. Lastly, it should be understood that the designer may override the selection, if the selection appears skewed because it is not based on enough information.

2. Selection Based on Only the Player's Head Model

This method270.60.2of selecting the complete stock helmet model270.4is similar to the above process170.60.2of the complete stock helmet model170.4. However, this method270.60.2is different from the above method170.60.2because this method270.60.2does not perform steps170.60.2.26-170.60.2.36due to the fact that the player profile220.99does not contain impact matrixes/scores. As discussed above, the only graphical representation of the complete stock helmet models270.4that passes each of these tests is shown inFIG. 27. In other words, the complete stock helmet model270.4.4shown inFIG. 27satisfies: (i) the MCS270.20.2.4and the maximum surface270.20.4.4because outer surface220.70.99.2of the complete head model220.70.99does not extends through these surfaces270.20.2.4,270.20.4.4and (ii) the minimum surface70.20.6.4because the outer surface220.70.99.2of the complete head model220.70.99extends through this surface270.20.6.4. Because the complete stock helmet model270.4.4passed each of the above tests, this complete stock helmet model270.4.4will pass on to the analysis contained withinFIG. 23in step270.60.2.24.

Also, similar to the above disclosure, there may only be one complete stock helmet model270.4that fits the player or there may be multiple complete stock helmet models270.4that fit the player. As shown in270.60.2.26, a single complete stock helmet model270.4will be identified because the complete stock helmet models170.4were created based upon all players. In this situation, the designer does not need to analyze or reference the protective sports helmet that the player selected in connection with step50because there is only one complete stock helmet model170.4that is available for selection. Alternatively, as shown in270.60.2.28-270.60.2.28.32, multiple complete stock helmet models270.4will be identified because the complete stock helmet models270.4were created after sorting the player's based upon position, level, or position and level. Thus, in this situation, the designer analyzes the protective sports helmet that the player selected in connection with step50and recommends the complete stock helmet model270.4based on that selection in steps270.60.2.34-270.60.2.40. For example, the designer will select the complete stock helmet model270.4that best matches the player's head model220.70.99and then the designer may select a quarterback varsity helmet, if the player picked a position and level specific helmet in step50.78. Alternatively, the designer may select the complete stock helmet model270.4that best matches the player's head model220.70.99and then the designer may select a youth helmet, if the player picked a level specific helmet in step50.76. It should be understood that a position and level specific complete stock helmet model270.4may not be available based on the size of the player's head. In this situation, the system will provide the designer with the closest available options that provide the best fit for the player even if they are not within the selected position or level.

3. Selection Based on Only the Player's Impact Matrix/Score

In contrast to the above methods170.60.2,270.60.2, the complete stock helmet model370.4may be selected by considering how the complete stock helmet model370.4fits but prioritizing the match between the player's impact matrix/score320.8.99over the fit in the process described in370.60.2. The first set in this process is receiving basic head measurements about the player. Typically, these head measurements are taken with measuring tape and are used to roughly determine (e.g, +/−¼ inch) the circumference of the player's head. These rough head measurements allow the system to select a helmet shell and energy attenuation assemblies that are designed to fit within that helmet shell. The player's impact matrix/score320.8.99is then compared against the impact matrix/score that is associated with each energy attenuation assembly370.40. Based on this comparison, the system recommends a complete stock helmet model370.4that fits the player's head but prioritizes the player's impact matrix/score320.8.99. For example, the system might recommend a helmet that is slightly larger than would have been recommended in the methods that are described above because the slightly larger shell can accommodate an energy attenuation assembly370.40that better matches the player's impact matrix/score320.8.99. Alternatively, the system might recommend a helmet that is slightly smaller (e.g., may place the outer surface of the player's head through the maximum surface but not beyond the MCS) than would have been recommended in the methods that are described above because the slightly smaller shell can accommodate an energy attenuation assembly370.40that better matches the player's impact matrix/score320.8.99.

Upon the completion of at least one of the above methods of selecting a complete stock helmet model170.4,270.4,370.4, the physical components that are associated with the complete stock helmet model170.4,270.4,370.4can be identified and shipped to the player in step199B,299B,399B. Alternatively, the complete stock helmet model170.4,270.4,370.4can be used below in connection with developing a custom energy attenuation assembly.

ii. Selection of a Combination of Stock Helmet Components from a Plurality of Combinations of Stock Helmet Components

In contrast to the above methods170.60.2,270.60.2,370.60.2of selecting a complete stock helmet model170.4,270.4,370.4, the following method discloses selecting individual stock helmet components that best match the player's profile120.99,220.99,320.99. This method170.70.2,270.70.2,370.70.2may be beneficial because it provides the designer with additional combinations of helmet shells and energy attenuation assemblies that may not have been available as complete stock helmet models170.4,270.4,370.4. However, these combinations have not been specifically designed based upon a selected group of players and thus the combinations do not include specific data about the minimum surface, the maximum surface, or the impact matrixes/scores. Nevertheless, these helmet components include other information (e.g., thickness, compression and deflection (CD) curves, etc.) that can provide the designer with suggestions about the functionality of the helmet components.

Referring toFIG. 28, the first step in this process170.70.2,270.70.2,370.70.2is the selection of a helmet shell from the plurality of helmet shells in step170.70.2.2,270.70.2.2,370.70.2.2. If the complete head model120.70.99,220.70.99is available, then this model120.70.99,220.70.99can be used to select the helmet shell. In particular, the MCS170.20.2,270.20.2for a first helmet shell can be compared against the complete head model120.70.99,220.70.99in step170.70.2.2.2,270.70.2.2.2. If the MCS170.20.2,270.20.2is satisfied, then a smaller helmet shell size is chosen in step170.70.2.2.4,270.70.2.2.4. This process starts over again with this smaller helmet shell and will continue until the MCS is not satisfied. Once the MCS is not satisfied, then a larger helmet size is chosen in step170.70.2.2.6,270.70.2.2.6. The MCS170.20.2,270.20.2that is associated with this larger helmet shell is then compared with the complete head model120.70.99,220.70.99. If the MCS170.20.2,270.20.2is satisfied, then the helmet shell is selected in step170.70.2.2.8,270.70.2.2.8. Alternatively, if the MCS170.20.2,270.20.2is not satisfied for this larger helmet shell, then the above process is repeated until the MCS170.20.2,270.20.2is satisfied. This process helps ensure that the smallest size helmet shell is chosen that fits the player (e.g., the player's head does not extend through or beyond the MCS170.20.2,270.20.2). Alternatively, if the complete head model120.70.99,220.70.99is not available (e.g., a player profile320.99that does not contain this information), then the rough measurements should be taken using the tape measure and those measurements should be utilized to choose the shell size in step370.70.2.2.2.

After the helmet shell size has been chosen in step170.70.2.2,270.70.2.2,370.2.2, then the energy attenuation assembly170.40,270.40,370.40is selected from the plurality of energy attenuation assemblies in step170.70.2.4,270.70.2.4,370.70.2.4. First, all energy attenuation members that fit within that helmet shell should be identified in step170.70.2.4.2,270.70.2.4.2,370.70.2.4.2. Next, the thicknesses of the energy attenuation member are chosen by aligning the inner surface of the energy attenuation members with the inset modified surface120.70.99.4,220.70.99.4in step170.70.2.4.4,270.70.2.4.4,370.70.2.4.4. Aligning these surfaces will help ensure that the energy attenuation members will be slightly compressed, prior to the player receiving an impact. This compression of the energy attenuation members prior to the player receiving an impact or pre-compression causes pressure to be exerted on the player's head when the helmet is worn by the player. In other words, an interference fit is formed between the energy attenuation assembly2000,3000and the player's head, when the helmet is worn by the player. This interference fit helps ensure that the helmet remains in place during play. Otherwise, without this interference fit, the helmet would not provide the desired fit (e.g., it would feel loose or uncomfortable on the player's head). Generally, the pressure exerted on the player's head by the energy attenuation assembly2000,3000to create this interference fit should be between 1 psi and 10 psi.

Once the thickness of the energy attenuation members is selected in step170.70.2.4.4,270.70.2.4.4,370.70.2.4.4, the next step in this process is to select the performance type of the energy attenuation members in step170.70.2.4.6,270.70.2.4.6,370.70.2.4.6. Selecting the performance type of the energy attenuation members may be based upon the player's level, player's position, player's position and level, or based upon the player's impact matrix/score. Hypothetically, it may be desirable to select an energy attenuation member that has a higher CD for a player that experiences high velocity impacts. This may be desirable because the higher CD energy attenuation member can absorb more energy before it bottoms-out. Alternatively, it may be desirable to have an energy attenuation member that has a lower CD for a player that experiences numerous low velocity impacts. After step170.70.2.4.4,270.70.2.4.4,370.70.2.4.4is completed, the physical components that are associated with the selected stock helmet components can be identified and shipped to the player in step199A,299A,399A. Alternatively, the selected stock helmet components can be used below in connection with developing a custom energy attenuation assembly.

iii. Selection of a Components that are Associated with a Complete Stock Helmet

In a further alternative embodiment, the above methods may be combined where the designer first selects a complete stock helmet170.4,270.4,370.4from the plurality of stock helmets170.4,270.4,370.4that best fits the player's head model120.70.99in step170.80,270.80,370.80. After the selection of the complete stock helmet170.4,270.4,370.4, the designer then may be provided with a number of stock helmet components (e.g., energy attenuation members) that function within the selected complete stock helmet and provide slightly different properties. The designer can then select the stock helmet components that best fit the player's profile120.99,220.99,320.99. Upon the completion of this step, the physical components that are associated with the selected stock helmet components can be identified and shipped to the player in step199A,299A,399A. Alternatively, the selected stock helmet components can be used below in connection with developing a custom energy attenuation assembly. It should be understood that the above described methods of selecting a complete stock helmet model170.4,270.4,370.4and stock helmet components are merely exemplary and as such can be combined or performed in a different order. Additionally, steps in the above methods may be omitted or additional steps may be added.

F. Generation of Custom Energy Attenuation Assembly

1. Custom Shaped Energy Attenuation Assembly

A custom shaped (CS) energy attenuation assembly3000that best matches a player's head model120.70.99,220.70.99can be created by: (i) modifying the selected complete stock helmet model170.4,370.4or the selected stock helmet components, (ii) developing it from a selected helmet shell, or (iii) developing it from a fitting helmet. A CS energy attenuation assembly3000may be desirable because an optimized fit can improve the management of impact energies (e.g., both linear and rotational energies). Discussed below are multiple methods of creating a CS helmet model280.50.

A) Custom Shaped Energy Attenuation Assembly Created from the Selected Stock Helmet or Stock Helmet Components

As described above in connection with step170.50,270.50, the selected complete stock helmet model170.4,270.4or the selected stock helmet components is the stock helmet model170.4,370.4or the selected stock helmet components that best match the player's profile120.99,20.99. Depending on the player's selection in step50and the above analysis, the selected stock helmet model170.4,370.4or the selected stock helmet components may be derived from: (i) all players, (ii) only player's that play at a similar level to the player, (iii) only player's that play a similar position to the player, or (iv) only player's that play a similar position and a similar level to the player. Thus, in some situations, the below analysis may be performed on a complete stock helmet model170.4,370.4or stock helmet components that have already been optimized for players that have attributes that are similar to the player. In these situations, the number of changes that are made by the below analysis may be reduced. In other situations, the selected stock helmet model170.4,370.4or the selected stock helmet components may not have been optimized for players that have attributes that are similar to the player.

The formation of the CS energy attenuation assembly3000starts by generating a CS helmet model280.50of the CS energy attenuation assembly3000in connection with180.10,280.10. Referring toFIG. 29, the first step in creating the CS helmet model280.50is the importation of the digital files associated with the selected complete stock helmet models170.4,270.4or the selected stock helmet components from steps170.60,270.60,170.70,270.70,170.80,270.80in step180.10.2,280.10.2. Next, the player's complete head model120.70.99,220.70.99is imported and aligned, using any of the methods that are described above, with the imported digital files associated with the selected complete stock helmet models170.4,270.4or the selected stock helmet components in step180.10.4,280.10.4. An exemplary graphical representation of this is shown inFIG. 30.

Once the files have been imported and aligned, the inner surface170.40.2,270.40.2of the energy attenuation assembly170.40,270.40is modified to match the modified surface120.70.99.4,220.70.99.4of the player's head model120.70.99,220.70.99in step180.10.6,280.10.6. In other words, the topography of the front wall or inner surface170.40.2,270.40.2of the energy attenuation assembly170.40,270.40substantially matches the modified surface120.70.99.4,220.70.99.4of the player's head model120.70.99,220.70.99. The inner surface170.40.2,270.40.2of the energy attenuation assembly170.40,270.40is not aligned with the outer surface120.70.99.2,220.70.99.2of the player's head/complete head model170.99,270.99because this would not create an interference fit between the player's head and the energy attenuation assembly3000, when the helmet1000was worn by the player. A graphical representation of aligning these surfaces is shown inFIG. 31.

Once the inner surface170.40.2,270.40.2of the energy attenuation assembly170.40,270.40is modified to match the modified surface120.70.99.4,220.70.99.4of the player's complete head model120.70.99,220.70.99in step180.10.6,280.10.6, the system checks to ensure that the changes to the selected complete stock helmet model170.99,270.99or selected stock helmet components have not negatively affected the performance of the selected complete stock helmet model170.99,270.99or selected stock helmet components in step180.10.8,280.10.8. Typically, the above modification to the energy attenuation assembly170.40,270.40only require modifying the fitting region of the energy attenuation assembly170.40,270.40. Thus, these modifications typically do not impact the energy attenuation region of the energy attenuation assembly170.40,270.40and therefore do not make significant alterations to the performance of the helmet. However, if the fitting region is increased over a predefined distance (e.g., the player's head is significantly smaller than the selected helmet model/components) or the energy attenuation region is altered (e.g., the player's head is significantly larger than the selected helmet model/components), then the performance of the energy attenuation assembly170.40,270.40may be impacted. To determine if this impact is a negative impact, the CS helmet model280.50is tested using the digital testing methods (e.g., dynamic FE testing) that are described in greater detail below in step180.10.8,280.10.8. If the changes or modifications to the energy attenuation assembly170.40,270.40did negatively impact the performance of the helmet, then the mechanical properties of the selected complete stock helmet model or helmet components are altered in step180.10.10,280.10.10. An example of how these mechanical properties may be altered is discussed below in connection with the creation of the CP energy attenuation assembly. Alternatively, if the changes or modifications to the energy attenuation assembly170.40,270.40did not negatively impact the performance of the helmet, then the CS helmet model280.50is outputted in step180.10.12,280.10.12.

B) Custom Shaped Energy Attenuation Assembly Created from a Helmet Shell

Instead of modifying a pre-selected energy attenuation assembly, as discussed above, to form the CS helmet model280.50, the CS helmet model280.50may be developed from scratch. In this embodiment, this process is to select the size of a helmet shell from a plurality of sizes in step180.15. Referring toFIG. 32, the MCS170.20.2,270.20.2for a first helmet shell can be compared against this complete head model120.70.99,220.70.99in step180.15.2,280.15.2. If the MCS170.20.2,270.20.2is satisfied, then a smaller helmet shell size is chosen in step180.15.4,280.15.4. This process starts over again with this smaller helmet shell and will continue until the MCS is not satisfied. Once the MCS is not satisfied, then a larger helmet size is chosen in step180.15.4,280.15.4. The MCS170.20.2,270.20.2that is associated with this larger helmet shell is then compared with the complete head model120.70.99,220.70.99. If the MCS170.20.2,270.20.2is satisfied, then the helmet shell180.15.8.99,280.15.8.99, is selected in step180.15.8,280.15.8. Alternatively, if the MCS170.20.2,270.20.2is not satisfied for this larger helmet shell, then the above process is repeated until the MCS170.20.2,270.20.2is satisfied. This process helps ensure that the smallest size helmet shell is chosen that fits the player (e.g., the player's head does not extend through or beyond the MCS170.20.2,270.20.2).

Next, the selected helmet shell180.15.8.99,280.15.8.99is compared against the complete head model120.70.99,220.70.99. Based on this comparison, a solid is generated that extends between the modified surface120.70.99.4,220.70.99.4of the player's head model120.70.99,220.70.99and the inner surface170.30.2of the helmet shell170.30in step180.15.10,280.15.10. An energy attenuation template is then applied to the solid in step180.15.12,280.15.12. In this step180.15.12,280.15.12, the application of the energy attenuation template forms an arrangement of sidewalls. Specifically, these sidewalls extend between the modified surface120.70.99.4,220.70.99.4of the player's head model120.70.99,220.70.99and the inner surface170.30.2of the helmet shell170.30. In other words, the side walls extend in the Z direction and away from the outer surface of the player's head model120.70.99,220.70.99. In the embodiments shown herein, the sidewalls that form the arrangement of sidewalls are positioned at various angles to one another, which aids in how the energy attenuation members interact with one another.

After the sidewall arrangement is defined in180.15.12,280.15.12, fillets are applied to edges of the sidewalls that is positioned adjacent to the complete head model120.70.99,220.70.99in step180.15.14,280.15.14. These fillets form the shoulders170.40.20,270.40.20of the energy attenuation members170.40. A graphical representation of the application of these fillets is shown inFIG. 33. Specifically, inFIG. 33, the image shown on the left side of the page is the result from step180.15.10,280.15.12, which includes an arrangement of side walls180.15.10.2,280.15.10.2, a front wall180.15.10.4,280.15.10.4that matches the modified surface120.70.99.4,220.70.99.4of the player's head model120.70.99,220.70.99, and rear wall180.15.10.6,280.15.10.6that matches the inner surface170.30.2of the helmet shell170.30. The image on the right side of the page is the results from step180.15.12,280.15.12, wherein the edges180.15.10.8,180.15.10.8of the side walls180.15.10.2,280.15.10.2that is positioned adjacent to the complete head model120.70.99,220.70.99are rounded. The creation of these shoulders170.40.20,270.40.20is desirable because it removes hard edges from the energy attenuation assembly170.40that may interact with the player's head, which increases the comfort of the helmet.

The CS helmet model280.50is finalized by providing the desired energy attenuation specification for each energy attenuation member within the energy attenuation assembly170.40in step180.15.16,280.15.16. These performance specifications may include, but is not limited to, (i) force absorption or load-compression curve/measurement, (ii) a compression deflection curve/measurement, (iii) a compression curve/measurement, (iv) a tensile strength curve/measurement, and/or (v) elongation curve/measurement. To create one or more of these performance specifications, the designer may collect data using methods or techniques that include, but are not limited to: (i) historical knowledge, (ii) data collected by placing sensors in a headform and testing the helmet using: (A) a linear impactor, (B) a drop tester, (C) a pendulum tester, or (D) other similar types of helmet testing apparatuses, (iii) data collected by placing sensors between the headform and the energy attenuation assembly and testing the helmet using the above apparatuses, (iv) data collected by placing sensors between the energy attenuation assembly and the helmet shell and testing the helmet using the above apparatuses, (v) data collected by placing sensors on the external surface of the shell and testing the helmet using the above apparatuses, (vi) helmet standards (e.g., NOCSAE), (vii) data collected from software programs using mathematical models (e.g., finite element analysis, neural networks, or etc.) of the helmet, faceguard, and/or energy attenuation assembly, (viii) HIE data collected by the proprietary technologies owned by the assignee of the present Application, which includes the systems disclosed in U.S. patent application Ser. No. 13/603,319 and U.S. Pat. Nos. 6,826,509, 7,526,389, 8,797,165 and 8,548,768, (ix) data collected using ASTM D3574 testing protocols, including but not limited to, Tests B1, C, E, F, X6, 13, M, (x) data collected using ISO 3386 testing protocol, (xi) data collected using ISO 2439 testing protocol, (xii) data collected using ISO 1798 testing protocol, (xiii) data collected using ISO 8067 testing protocol, (xiv) data collected using ASTM D638 testing protocol, (xv) data collected using ISO 37 testing protocol, (vi) data collected using ASTM D395 testing protocol, or (xvii) other similar techniques that can be used to gather data about the mechanical response of a material. Once the CS helmet model280.50is finalized, it can be outputted for use in the next steps in designing and manufacturing the helmet1000.

C) Custom Shaped Energy Attenuation Assembly Created from a Fitting Helmet Model

In an alternative embodiment, the CS helmet model280.50may be developed from a fitting helmet model. Specifically, the fitting helmet model is a standard helmet that includes an energy attenuation assembly that has the arrangement of side walls180.15.10.2,280.15.10.2and rear wall180.15.10.6,280.15.10.6that matches the inner surface170.30.2of the helmet shell170.30. The front wall of the energy attenuation assembly is designed to extend past any reasonable position and may even through a portion of the helmet shell. In other words, the entire inner cavity of the helmet is occupied by the energy attenuation assembly. The reason for this configuration is discussed in greater detail below. The first step in this alternative embodiment is to select a helmet shell that fits the player. This may be done in the same manner as described above in connection withFIG. 32.

Once the helmet shell is selected, the player's head model120.70.99,220.70.99is then placed within this cavity and aligned with the selected helmet shell180.15.8.99,280.15.8.99using the above described techniques. The system then determines the intersection between the modified surface120.70.99.4,220.70.99.4of the player's head model120.70.99,220.70.99and the energy attenuation members. This intersecting surface becomes the front wall180.15.10.4,280.15.10.4of the energy attenuation assembly that matches the modified surface120.70.99.4,220.70.99.4of the player's head model120.70.99,220.70.99. In other words, the topography of the front wall or inner surface of the energy attenuation assembly substantially matches the modified surface120.70.99.4,220.70.99.4of the player's head model120.70.99,220.70.99.

After the inner surface of the energy attenuation assembly is determined, fillets are applied to edges of the sidewalls that is positioned adjacent to the complete head model120.70.99,220.70.99. As discussed above in connection withFIG. 33, these fillets form the shoulders170.40.20,270.40.20of the energy attenuation members170.40. The CS helmet model280.50is then finalized by providing the desired energy attenuation specification from the fitting helmet model. It should be understood that these energy attenuation specifications may have been derived from any of the techniques disclosed herein.

2. Custom Performance Energy Attenuation Assembly

A custom performance (CP) energy attenuation assembly that takes into account the player's impact matrix/score320.8.99can be created by: (i) modifying the selected complete stock helmet model170.4,370.4or the selected stock helmet components or (ii) generating it from scratch. A CP energy attenuation assembly may be desirable because it can provide improved impact energy (e.g., both linear and rotational energies) management. As described in greater detail below, the CP energy attenuation assembly may be designed and developed using various different methodologies, such as: (i) a response surface methodology180.28.2,380.28.2, (ii) a brute force methodology180.28.4,380.28.2, (iii) hybrid methodology180.28.6,380.28.6, or (iv) other optimization methodology.

A) Custom Performance Energy Attenuation Assembly Created from the Selected Stock Helmet or Stock Helmet Components

As described above in connection with step170.50,370.50, the selected complete stock helmet model170.4,370.4or the selected stock helmet components is the stock helmet model170.4,370.4or the selected stock helmet components that best match the player's profile120.99,20.99. Depending on the player's selection in step50and the above analysis, the selected stock helmet model170.4,370.4or the selected stock helmet components may be derived from: (i) all players, (ii) only player's that play at a similar level to the player, (iii) only player's that play a similar position to the player, or (iv) only player's that play a similar position and a similar level to the player. Thus, in some situations, the below analysis may be performed on a complete stock helmet model170.4,370.4or stock helmet components that have already been optimized for players that have attributes that are similar to the player. In these situations, the number of changes that are made by the below analysis may be reduced. In other situations, the selected stock helmet model170.4,370.4or the selected stock helmet components may not have been optimized for players that have attributes that are similar to the player.

1) Response Surface Methodology

Now referring toFIGS. 34A-B, the first step in creating this CP helmet model180.28.99,380.28.99using a response surface methodology180.28.2,380.28.2is to determine an energy attenuation layer testing protocol180.28.2.1.99,380.28.2.1.99in step180.28.2.1,380.28.2.1. To develop the energy attenuation layer testing protocol180.28.2.1.99,380.28.2.1.99, the designer may import various testing protocols, such as: (i) the NFL Linear Impactor Helmet Test Protocol, which was authored by James Funk, Jeff Crandall, Michael Wonnacott, and Chris Withnall and published on Feb. 1, 2017, which is incorporated herein by reference, (ii) the Adult Football STAR Methodology, which was authored by Abigail Tyson and Steven Rowson and published on Mar. 30, 2018, which is incorporated herein by reference, (iii) historical knowledge, or (iv) a combination of each of these test protocols.

After importing these protocols, the designer may then compare the protocols to the player's profile120.99,320.99to ensure that the energy attenuation layer testing protocol180.28.2.1.99,380.28.2.1.99properly accounts for the player's impact history, playing style, medical history, etc. If the protocol is different from the player's profile120.99,320.99, then the designer may alter the protocol to better match the player's profile120.99,320.99. For example, Virginia Tech assumes that a player will experience 83 impacts that are at 3.0 m/s condition, 18 impacts that are at 4.6 m/s, and 4 impacts that are at 6.1 m/s during a season. The impacts are then evenly weighted (e.g., 25%) based on the impact location (e.g., front, front boss, side, back). Unlike these assumed impacts, the player profile120.99,320.99may include: (i) 53 impacts that are at 3.0 m/s condition, 35 impacts that are at 4.6 m/s, and 17 impacts that are at 6.1 m/s during a season. Accordingly, the designer will alter the testing protocol by altering the weights given to each location (e.g., 32% for the back, 23% for the side, 26% for the front, and 19% for the front boss). By taking the player's profile120.99,320.99into account when developing180.28.2.1.99,380.28.2.1.99, the performance of the energy attenuation assembly will be tailored or bespoke to the player. It should be understood that this same process of developing the energy attenuation layer testing protocol180.28.2.1.99,380.28.2.1.99will be used in connection with the other methods of developing a CP energy attenuation assembly, such as brute force methodology180.28.4,380.28.2, hybrid methodology180.28.6,380.28.6, or other types of optimization methodology.

The next steps are designed to test the selected complete stock helmet model170.4,370.4or the selected stock helmet components with their current configuration along with variations of these components to determine the optimal configuration of the energy attenuation assembly in light of the player's profile120.99,320.99. The first step in this test is to extract the dependent variables in step180.28.2.4.4,380.28.2.4.4from the selected complete stock helmet model170.4,370.4and the headform that is associated with the selected complete stock helmet model170.4,370.4. Next, the designer determines a range for the independent variables180.28.2.4.2.99,380.28.2.4.2.99(seeFIG. 35) based upon the selected complete stock helmet model170.4,370.4in step180.28.2.4.2,380.28.2.4.2. One exemplary way of determining these ranges is by adding and subtracting 25% to the values contained within the selected complete stock helmet model170.4,370.4. It should be understood that other ways of determining these ranges are contemplated by this disclosure, including utilizing historical knowledge. An example of the ranges that may be used in connection with the independent variables is shown inFIG. 35.

Next, a Plackett-Burman design to select the values for the independent variables in step180.28.2.4.6,380.28.2.4.6. These values will be spaced across the entire range. Next, rough testing helmets180.28.2.4.6.99,380.28.2.4.6.99are created based upon: (i) digital headform prototypes associated with the selected complete stock helmet model170.4,370.4, (ii) complete stock helmet model170.4,370.4, and (iii) the independent variables determined in step180.28.2.4.2,380.28.2.4.2. It should be understood that the rough testing helmets180.28.2.4.6.99,380.28.2.4.6.99may be created in the form of a finite element model or any other digital model that contains mechanical properties and shape information. It should also be understood that when an independent variable is altered from the value that is contained within the complete stock helmet model170.4,370.4, this change may cause a ripple effect that requires the alteration of other aspects of the rough testing helmets180.28.2.4.6.99,380.28.2.4.6.99. For example, if the compression ratio of the side member is changed, then maximum surface170.20.4,270.20.4may be altered to ensure that the pressure exerted on the head of the player is not too great (e.g., greater than 10 psi). These rough testing helmets180.28.2.4.6.99,380.28.2.4.6.99are then subjected to the energy attenuation layer testing protocol180.28.2.1.99,380.28.2.1.99, wherein the following values are recorded for each test within the energy attenuation layer testing protocol180.28.2.1.99,380.28.2.1.99: (i) peak linear acceleration, (ii) peak rotational acceleration, (iii) peak HITsp, and (iv) if the energy attenuation assembly bottomed out (e.g., could not absorb any additional force) or if the energy attenuation assembly did not bottom out, then the distance that the energy attenuation assembly before it would bottom out in step180.28.2.4.10,380.28.2.4.10. It should be understood that one of the rough testing helmets180.28.2.4.6.99,380.28.2.4.6.99will be directly based upon the selected complete stock helmet model170.4,370.4.

Next, the most significant independent variables are determined in step180.28.2.4.12,380.28.2.4.12based upon applying the energy attenuation layer testing protocol180.28.2.1.99,280.28.2.1.99in connection with each rough testing helmet180.28.2.4.6.99,380.28.2.4.6.99. Once the most significant independent variables are determined, then a refined experimental design can be undertaken in step180.28.2.4.14,380.28.2.4.14. Examples of more refined designs include: (i) Full Factorial Design, (ii) Box-Behnken Design, (iii) Central Composite Design, or (iv) a Doehlert Matrix Design. Next, refined testing helmets180.28.2.4.14.99,380.28.2.4.14.99are created based upon: (i) digital headform prototypes associated with the selected complete stock helmet model170.4,370.4, (ii) selected complete stock helmet model170.4,370.4, and (iii) the independent variables determined in step180.28.2.4.12,380.28.2.4.12. It should be understood that the refined testing helmets180.28.2.4.14.99,380.28.2.4.14.99may be created in the form of a finite element model or any other digital model that contains mechanical properties and shape information. Also, like above, it should also be understood that when an independent variable is altered from the value that is contained within the selected complete stock helmet model170.4,370.4, this change may cause a ripple effect that requires the alteration of other aspects of the refined testing helmets180.28.2.4.14.99,380.28.2.4.14.99. These refined testing helmets180.28.2.4.14.99,380.28.2.4.14.99are then subjected to the energy attenuation layer testing protocol180.28.2.1.99,380.28.2.1.99, wherein the following values are recorded for each test within the energy attenuation layer testing protocol180.8.2.1.99,380.28.2.1.99: (i) peak linear acceleration, (ii) peak rotational acceleration, (iii) peak HITsp, and (iv) if the energy attenuation assembly bottomed out (e.g., could not absorb any additional force) or if the energy attenuation assembly did not bottom out, then the distance that the energy attenuation assembly before it would bottom out in step180.28.2.4.18,280.28.2.4.18.

The data from testing the refined testing helmets180.28.2.4.14.99,380.28.2.4.14.99are fitted using mathematical functions, such as polynomial function or an advanced surface fitting function (e.g., Kigring, or radial basis function, or a combination of advanced surface fitting functions). Exemplary fitted surfaces180.28.2.4.20.99,380.28.2.4.20.99are shown inFIG. 36for a few different refined testing helmets. After a surface is determined for each refined testing helmet180.28.2.4.14.99,380.28.2.4.14.99in step180.28.2.6,380.28.2.6, over a surface180.28.2.4.20.99,380.28.2.4.20.99overlaid upon one another in step180.28.2.8,380.28.2.8. Overlaying these surfaces180.28.2.4.20.99,380.28.2.4.20.99will allow the designer to identify the optimized region180.28.2.4.20.99.2,380.28.2.4.20.99.2by locating where maximum values associated with each surface overlap one another in step180.28.2.10,380.28.2.10. If the maximum values do not overlap one another, then the designer can determine an average between these maximum values or may use historical knowledge in combination with the maximum values to select an optimized region. Once the optimized region is selected, then the designer can determine the independent values that are associated with this region, which can be combined to create response surface testing helmets180.28.4.12.99,380.28.4.12.99.

Once the independent values have been derived from the optimized region180.28.2.4.20.99.2,380.28.2.4.20.99.2, then the designer needs to verify that the response surface testing helmet180.28.4.12.99,380.28.4.12.99meets all helmet standard(s) (e.g., player group—shape+impact based helmet standard, NOCSAE, and etc.). Once it has been verified that the response surface testing helmet180.28.4.12.99,380.28.4.12.99meets all helmet standard(s), the response surface testing helmet180.28.4.12.99,380.28.4.12.99may undergo a visual inspection to ensure that it meets all manufacturing, marketing, and sales requirements. If the response surface testing helmet180.28.4.12.99,380.28.4.12.99does not meet any of these requirements, then the response surface testing helmet180.28.4.12.99,380.28.4.12.99may be altered to meet these requirements. Once the response surface testing helmet180.28.4.12.99,380.28.4.12.99meets these requirements, then this response surface testing helmet180.28.4.12.99,380.28.4.12.99is added to a collection of response surface testing helmets180.28.4.12.99,380.28.4.12.99, which will be compared against one another in the following steps.

Each of the above steps may optionally then be repeated for each method of manufacturing (e.g., foam, Precision-Fit, and Additive Manufacturing) in step180.28.2.14,380.28.2.14. These methods must be performed individually because each manufacturing method has inherent limitations that need to be accounted for when selecting the ranges of the independent variables180.28.2.4.2.99,380.28.2.4.2.99. Once response surface testing helmets180.28.4.12.99,380.28.4.12.99are created for each type of manufacturing process in step180.28.2.14,380.28.2.14, the response surface testing helmets180.28.4.12.99,380.28.4.12.99may be compared against one another to determine if their performance, in connection with the energy attenuation layer testing protocol180.28.2.1.99,380.28.2.1.99, is substantially similar in step180.28.2.16,380.28.2.16. If the response surface testing helmet180.28.4.12.99,380.28.4.12.99performances are substantially similar, then the designer can optimize the manufacturing methods in step180.28.2.18,380.28.2.18by combining these manufacturing methods. For example, the designer may determine the side members of the energy attenuation assembly that are manufactured using a foam process perform substantially similar side members of the energy attenuation assembly that are manufactured using an additive process.

Additionally, the designer may determine the front members of the energy attenuation assembly that are manufactured using a foam process perform completely different than front members of the energy attenuation assembly that are manufactured using an additive process. Based on these examples, the designer may combine these manufacturing methods in the creation of the custom performance helmet model380.28.99. Alternatively, the designer may determine that the members made using the additive manufacturing process perform substantially better than members manufactured with other methods. In this example, the designer will create the custom performance helmet model380.28.99using only the additive manufactured members. Once the designer has optimized manufacturing in step180.28.2.18,380.28.2.18, the custom performance helmet model380.28.99is outputted for use in the next steps in designing and manufacturing the helmet1000. It should be understood that the CP helmet model380.28.99may take the form of a finite element model or any other digital model that contains mechanical properties and shape information that can be used later in the digital testing.

2) Brute Force Methodology

Instead of using a response surface methodology to create the CP helmet model380.28.99, a brute force methodology180.28.4,380.28.4may be used. Specifically, such a brute force methodology is disclosed inFIG. 37. The first step in creating the CP helmet model380.28.99using brute force methodology180.28.4,380.28.4is to determine an energy attenuation layer testing protocol in step180.28.2.1,380.28.2.1. This is done in the same manner as described above in connection withFIGS. 34A-34B. The next steps are designed to test the selected complete stock helmet model170.4,370.4with its current configuration along with variations of the selected complete stock helmet model170.4,370.4to determine the optimal configuration of the energy attenuation assembly in light of the player's profile120.99,320.99. The first step in these tests is to extract the dependent variables in step180.28.4.2.4,380.28.4.2.4from the selected complete stock helmet model170.4,370.4, the digital headform that is associated with the stock helmet model170.4, and extract the independent variables180.28.4.2.2.99,380.28.4.2.2.99based upon the selected complete stock helmet model170.4,370.4in step180.28.4.2.2,380.10.4.2.2.

Next, the designer will select a number of combinations of independent variables. These combinations may be based on: (i) historical knowledge, (ii) a repetitive brute force process of picking a set of variables, testing the set of variables, selecting a new set of variables based on the outcome of the test, (iii) a combination of the above methods. Regardless of how the independent variables are selected, they will be used to create rough testing helmets180.28.2.4.8.99,380.28.2.4.8.99. These rough testing helmets are then subjected to the energy attenuation layer testing protocol180.28.2.1.99,380.28.2.1.99, wherein the following values are recorded for each test within the energy attenuation layer testing protocol180.28.2.1.99,380.28.2.1.99: (i) peak linear acceleration, (ii) peak rotational acceleration, (iii) peak HITsp, and (iv) if the energy attenuation assembly bottomed out (e.g., could not absorb any additional force) or if the energy attenuation assembly did not bottom out, then the distance that the energy attenuation assembly before it would bottom out in step180.28.4.2.8,380.10.4.2.8. It should be understood that one of the testing helmets will be directly based upon the selected complete stock helmet model170.4,370.4.

After the rough testing helmet is determined for each set of variables in step180.28.4.4,380.28.4.4, the designer selects the best performing rough testing helmets in step180.28.4.6,380.28.4.6to create a brute force testing helmet180.28.4.8.99,380.28.4.8.99in step180.28.4.8.99,380.28.4.8.99. Next, the designer needs to verify that the brute force testing helmet180.28.4.8.99,280.28.4.8.99meets all helmet standard(s) (e.g., player group—shape+impact based helmet standard, NOCSAE, and etc.). Once it has been verified that the brute force testing helmet180.28.4.8.99,380.28.4.8.99meets all helmet standard(s), the brute force testing helmet180.28.4.8.99,380.28.4.8.99may undergo a visual inspection to ensure that it meets all manufacturing, marketing, and sales requirements. If the brute force testing helmet180.28.4.8.99,380.28.4.8.99does not meet any of these requirements, then the brute force testing helmet180.28.4.8.99,380.28.4.8.99may be altered to meet these requirements. Once the brute force testing helmet180.28.4.8.99,380.28.4.8.99meets these requirements, then the brute force testing helmet180.28.4.8.99,380.28.4.8.99is added to the collection of brute force testing helmets180.28.4.8.99,380.28.4.8.99, which will be compared against one another in the following steps.

Each of the above steps may optionally then be repeated for each method of manufacturing (e.g., foam, Precision-Fit, and Additive Manufacturing) in step180.28.4.10,380.28.4.10. These methods must be performed individually because each manufacturing method has inherent limitations that need to be accounted for when selecting the ranges of the independent variables180.28.4.2.2.99,380.28.4.2.2.99. Once brute force testing helmets180.28.4.8.99,380.28.4.8.99are created for each type of manufacturing process in step180.28.4.10,380.28.4.10, the brute force testing helmet180.28.4.8.99,380.28.4.8.99may be compared against one another to determine if their performance, in connection with the energy attenuation layer testing protocol180.28.2.1.99,380.28.2.1.99, is substantially similar in step180.28.2.12,380.28.2.12. If the brute force testing helmet180.28.4.8.99,380.28.4.8.99performances are substantially similar, then the designer can optimize the manufacturing methods in step180.28.4.14,380.28.4.14by combining these manufacturing methods. Once the designer has optimized manufacturing in step180.28.4.14,380.28.4.14, the CP helmet model380.28.99is outputted for use in the next steps in designing and manufacturing the helmet1000. It should be understood that the custom performance helmet model380.28.99may take the form of a finite element model or any other digital model that contains mechanical properties and shape information that can be used later in the digital testing.

Instead of just using a response methodology or a brute force methodology, the designer may desire to use a hybrid of these methodologies180.28.6. The perimeter of each energy attenuation member that is contained within the energy attenuation assembly of the selected complete stock helmet model170.4,370.4is determined in step180.28.6.4,380.28.6.4. Next, energy attenuation member models180.28.6.6.99,380.28.6.6.99are created using an energy attenuation engine to develop the internal structures for each energy attenuation member in step180.28.6.6,380.28.6.6. Additional details about the creation of these energy attenuation member models180.28.6.6.99,380.28.6.6.99are described in connection withFIG. 39. Referring toFIG. 39, this specific method starts with inputting the selected complete stock helmet model170.4,370.4along with the perimeter of each energy attenuation member. The energy attenuation engine utilizes this information to extract the mechanical properties that are associated with each energy attenuation member. Based on this extracted information, the energy attenuation engine determines the number and location of member regions. Next, the energy attenuation engine processes these regions to determine the properties (e.g., cell type, density, and angle) of these member regions.

The energy attenuation engine selects these member region variables based upon the information contained within its database or information that can be derived from information that is contained within its database. Information that may be contained within the energy attenuation engine database includes: (i) mechanical properties, (ii) thermal properties, (iii) manufacturing properties, and (iv) other relevant properties for combinations of the member region variables. These properties may be determined based upon: (i) actual data collected from physical measurements or (ii) theoretical data generated by predictive algorithms or learning algorithms. Examples of tests that may be utilized to generate actual data include, but are not limited to: (i) ASTM D3574 testing protocols, including but not limited to, Tests B1, C, E, F, X6, 13, M, (ii) ISO 3386 testing protocol, (iii) ISO 2439 testing protocol, (iv) ISO 1798 testing protocol, (v) ISO 8067 testing protocol, (vi) ASTM D638 testing protocol, (vii) ISO 37 testing protocol, (viii) ASTM D395 testing protocol, (ix) other types of compression analysis, (x) other types of elongation analysis, (xi) tensile strength analysis, or (xii) other similar techniques.

Referring to the member region variables, exemplary lattice cell types are shown inFIG. 39, lattice angle may vary between 0 degrees and 180 degrees. Additionally, the chemical compositions may include, but are not limited to: polycarbonate, acrylonitrile butadiene styrene (ABS), nylon, polylactic acid (PLA), acrylonitrile styrene acrylate (ASA), polyoxymethylene (POM), rigid polyurethane, elastomeric polyurethane, flexible polyurethane, silicone, thermoplastic polyurethane (TPU), Agilus® 30, Tango®, other similar thermoplastics, other light sensitive plastics or polymers (e.g., plastics that cure upon the exposure to certain wavelengths of light, such as UV light), any combination of the above materials with one another, where the materials are not blended together prior to the forming an extent of the protective sports helmet, any combination of the above materials with one another, where the materials are blended together prior to the forming of an extent of protective sports helmet, one or more of the above materials and a strength adding material (e.g, Kevlar or carbon fiber), where the materials are not blended together prior to the forming an extent of protective sports helmet, one or more of the above materials and a strength adding material (e.g, Kevlar or carbon fiber), where the materials are blended together prior to the forming an extent of protective sports helmets, hybrid of any of the disclosed material, or any other material that is specifically designed to absorb impact forces within a helmet.

Once member region variables are selected, then the energy attenuation member model180.28.6.6.99,380.28.6.6.99is created based upon these selected variables. Exemplary energy attenuation member models180.28.6.6.75,380.28.6.6.75are shown inFIG. 40. In these examples, the energy attenuation engine created a single member region for the front member of the energy attenuation assembly. The energy attenuation engine then analyzes various combinations of member region variables, some of these combinations are graphically shown inFIG. 40, in order to find a combination of member region variables that created an energy attenuation member model180.28.6.6.99,380.28.6.6.99that have mechanical properties that are similar to the energy attenuation member from the selected complete stock helmet model170.4,370.4. This process is then repeated for each energy attenuation member contained within the energy attenuation assembly.

It should be understood that the energy attenuation member models180.28.6.6.99,380.28.6.6.99may be created in the form of a finite element model or any other digital model that contains mechanical properties and shape information that can be used later in the digital testing. It should also be understood that the selection of the member regions and their associated member region variables are not limited to structures that can only be manufactured using additive manufacturing techniques. Instead, the energy attenuation engine may consider and utilize any one of the following materials: expanded polystyrene (EPS), expanded polypropylene (EPP), plastic, foam, expanded polyethylene (PET), vinyl nitrile (VN), urethane, polyurethane (PU), ethylene-vinyl acetate (EVA), cork, rubber, orbathane, EPP/EPS hybrid (Zorbium), brock foam, or other suitable material or blended combination or hybrid of materials. In using one of these materials, the member regions may be slightly altered to better represent the structures and properties of the select material.

Referring back toFIG. 38, the energy attenuation assembly of the selected complete stock helmet model170.4,370.4is replaced with an energy attenuation assembly created from the energy attenuation member models180.28.6.6.99,380.28.6.6.99. This combination is then tested using the energy attenuation layer testing protocol180.28.2.1,380.28.2.1, which takes into consideration the player's profile120.99,320.99in step180.28.6.8,380.28.6.8. The outcome of these tests is analyzed in step180.28.6.10,380.28.6.10to partition each energy attenuation member.FIG. 41shows an example of how the energy attenuation member model180.28.6.6.99,380.28.6.6.99may be dynamically tested and how this dynamic testing can be utilized to partition the energy attenuation member. In particular, this dynamic test suggested that the energy attenuation member be partitioned into four different segments. Where the first segment is shown in gray180.28.6.10A,380.28.6.10A, the second segment is shown in gray to light yellow180.28.6.10B,380.28.6.10B, the third segment is shown in yellow180.28.6.10C,380.28.6.10C, and the fourth segment is shown in green180.28.6.10D,380.28.6.10D. It should be understood that this is just an example of embodiment and the dynamic testing of other energy attenuation members in connection with other selected complete stock helmet models170.4,370.4may create different numbers and locations of member regions.

Referring back toFIG. 38, once the energy attenuation members are partitioned in step180.28.6.10,380.28.6.10, then the mechanical properties of each partitioned segment is optimized using one of the optimization methods described above, including response surface methodology180.28.2,380.28.2, brute force methodology180.28.4,380.28.4or another optimization methodology in step180.2.6.12,380.2.6.12. After step180.28.6.12,380.28.6.12is performed, the CP helmet model180.28.99,380.28.99are generated and prepared for the next steps in designing and manufacturing the helmet1000. It should be understood that the CP helmet model380.28.99may take the form of a finite element model or any other digital model that contains mechanical properties and shape information that can be used later in the digital testing.

Instead of performing steps180.28.6.6-180.28.6.10,380.28.6.6-380.28.6.10, a designer may elect to utilize a brute force partitioning approach in step180.28.6.30,380.28.6.30. This method allows the designer to select the number and location of the member regions. This selection may be based on historical knowledge or may be based on physical testing of helmets or physical testing of helmet components. For example, the designer may independently collect data from one of, or a combination of, the following: (i) placing sensors in a headform and testing the helmet using: (a) a linear impactor, (b) a drop tester, (c) a pendulum tester, or (d) other similar types of helmet testing apparatuses, (ii) placing sensors between the headform and the energy attenuation assembly and testing the helmet using the above apparatuses, (iii) placing sensors between the energy attenuation assembly and the helmet shell and testing the helmet using the above apparatuses, (iv) placing sensors on the external surface of the shell and testing the helmet using the above apparatuses, (v) using a linear impactor, a tensile strength machine, or another similar apparatus to test individual helmet components, (vi) using ASTM D3574 testing protocols, including but not limited to, Tests B1, C, E, F, X6, 13, M, (vii) using ISO 3386 testing protocol, (viii) using ISO 2439 testing protocol, (ix) data collected using ISO 1798 testing protocol, (x) using ISO 8067 testing protocol, (xi) using ASTM D638 testing protocol, (xii) using ISO 37 testing protocol, (xiii) using ASTM D395 testing protocol, or (xiv) other similar techniques.

FIGS. 42-43show exemplary component regions that were created using a brute force method. Specifically,FIG. 42shows six different embodiments of the rear combination member, which is split into partitions lengthwise using the brute force method. The first exemplary embodiment contained withinFIG. 42, which is labeled A and is in the upper right, contains two component regions. A first region is shown in green180.28.6.30.2.2,380.28.6.30.2.2, while the second region is shown in blue180.28.6.30.2.4,380.28.6.30.2.4. The second and fourth exemplary embodiment that are labeled B and D contains three component regions, wherein one is green180.28.6.30.2.2,380.28.6.30.2.2, one is blue180.28.6.30.2.4,380.28.6.30.2.4, and one is in between green and blue180.28.6.30.2.6,380.28.6.30.2.6. The third exemplary embodiment is labeled C and contains four component regions, wherein one is green180.28.6.30.2.2,380.28.6.30.2.2, one is blue180.28.6.30.2.4,380.28.6.30.2.4, and one is red180.28.6.30.2.8,380.28.6.30.2.8, and one is between green and red180.28.6.30.2.10,380.28.6.30.2.10. The fifth exemplary embodiment is labeled E and contains seven component regions, wherein one is green180.28.6.30.2.2,380.28.6.30.2.2, one is blue180.28.6.30.2.4,380.28.6.30.2.4, one is red180.28.6.30.2.8,380.28.6.30.2.8, one is between green and red180.28.6.30.2.10,380.28.6.30.2.10, one is between green and blue180.28.6.30.2.6,380.28.6.30.2.6, and one is yellow180.28.6.30.2.12,380.28.6.30.2.12. Lastly, the sixth exemplary embodiment is labeled F and contains four component regions, wherein one is green180.28.6.30.2.2,380.28.6.30.2.2, one is blue180.28.6.30.2.4,380.28.6.30.2.4, one is red180.28.6.30.2.8,380.28.6.30.2.8, and one is between green and blue180.28.6.30.2.6,380.28.6.30.2.6.

FIG. 43shows six different embodiments of the energy attenuation member, which is split into partitions lengthwise using the brute force method. The first and third exemplary embodiment contained withinFIG. 43, which are labeled A and C contain two component regions. A first region is shown in green180.28.6.30.4.2,380.28.6.30.4.2, while the second region is shown in blue180.28.6.30.4.4,380.28.6.30.4.4. In this example, the first region may have mechanical properties that are designed to increase the comfort of the fit, while the second region may have mechanical properties that are designed to absorb impacts. The second exemplary embodiment that is labeled B contains three component regions, wherein one is green180.28.6.30.4.2,380.28.6.30.4.2, one is blue180.28.6.30.4.4,380.28.6.30.4.4, and one is red180.28.6.30.4.8,380.28.6.30.4.8. The fourth exemplary embodiment is labeled D and contains five component regions, wherein one is green180.28.6.30.4.2,380.28.6.30.4.2, one is blue180.28.6.30.4.4,380.28.6.30.4.4, one is red180.28.6.30.4.8,380.28.6.30.4.8, one is between green and green180.28.6.30.4.6,380.28.6.30.4.6, and one is blue to yellow180.28.6.30.4.16,380.28.6.30.4.16. The fifth exemplary embodiment is labeled F contains five component regions, wherein one is green180.28.6.30.4.2,380.28.6.30.4.2, one is blue180.28.6.30.4.4,380.28.6.30.4.4, one is red180.28.6.30.4.8,380.28.6.30.4.8, one is between blue and green180.28.6.30.4.6,380.28.6.30.4.6, and one is between red and green180.28.6.30.4.10,380.28.6.30.4.10. The final exemplary embodiment is labeled E contains six component regions, wherein one is green180.28.6.30.4.2,380.28.6.30.4.2, one is blue180.28.6.30.4.4,380.28.6.30.4.4, one is red180.28.6.30.4.8,380.28.6.30.4.8, one is yellow180.28.6.30.4.12,380.28.6.30.4.12, one is orange180.28.6.4.18,380.28.6.30.4.18, and one is brown180.28.6.30.4.20,380.28.6.30.4.20.

Referring back toFIG. 38, once the energy attenuation members are partitioned in step180.28.6.30,380.28.6.30, then the mechanical properties of each partitioned segment is optimized using one of the optimization methods described above, including response surface methodology180.28.2,380.28.2, brute force methodology180.28.4,380.28.4, or another optimization methodology in step180.2.6.12,380.2.6.12. After step180.28.6.30,380.28.6.30is performed, the CP helmet model380.28.99is generated and prepared for the next steps in designing and manufacturing the player specific helmet.

B) Custom Performance Energy Attenuation Assembly Created from Scratch

In an alternative embodiment, the CS helmet model280.50may be created from scratch. In this embodiment, the designer may input the energy attenuation layer testing protocol180.28.2.1.99,380.28.2.1.99that was described above in connection with step180.28.2.1,380.28.2.1. After this energy attenuation layer testing protocol180.28.2.1.99,380.28.2.1.99, the system may utilize a brute force method (e.g., similar to the method discussed above), a dynamic FE engine, a learning algorithm, a neural network-based algorithm, or a combination of these to generate the best performing CS helmet model280.50in light of the energy attenuation layer testing protocol180.28.2.1.99,380.28.2.1.99.

3. Custom Performance and Custom Shaped Energy Attenuation Assembly

Custom performance and custom shaped (CP+CS) energy attenuation assembly can be created using a combination of the techniques and methodologies that were discussed above in connection with the creation of the CS energy attenuation assembly and the CP energy attenuation assembly. For the sake of brevity, the combination of these processes will not be disclosed again. Nevertheless, the creation of the CP+CS energy attenuation assembly starts by creating a digital model of the CP+CS energy attenuation assembly in connection with180.10. Once the digital model is created in step180.10, then the digital model is modified by the process disclosed in connection with forming the CP energy attenuation assembly. This modification creates the CP+CS helmet model180.28.99, which is prepared for the next steps in designing and manufacturing the player specific helmet.

G. Generate Player Specific Helmet Model

The next step in this method is to create the player specific helmet model190.12.99,290.12.99,390.12.99from: (i) the CS+CP helmet model180.28.99, (ii) CS helmet model280.50, or (iii) CP helmet model380.28.99. Details about the creation of the complete stock helmet models190.12.99,290.12.99,390.12.99are described in greater detail inFIG. 44. Referring now toFIG. 44, the first steps in this method are inputting the CS+CP, CS, or CP helmet models180.28.99,280.50,380.28.99and determining the perimeter of: (i) each energy attenuation member or (ii) each energy attenuation segment in step190.2,290.2,390.2. Next, CS+CP, CS, and CP helmet models180.28.99,280.50,380.28.99along with the perimeter of: (i) each energy attenuation member or (ii) each energy attenuation segment are entered into the energy attenuation engine to develop energy attenuation member models190.8.99,290.8.99,390.8.99in step190.8,290.8,390.8. The energy attenuation member models190.8.99,290.8.99,390.8.99are created using the same steps that are described above in connection withFIG. 39and for the sake of brevity will not be repeated here.

Below are a number of exemplary embodiments of the front energy attenuation member model that may be created in step190.8,290.8,390.8. In the first exemplary embodiment, the chemical composition and the structural makeup of the front energy attenuation member2010,3010may be consistent throughout the model. Specifically, the front energy attenuation member model may be comprised of: (i) a consistent blend of two types of polyurethane and (ii) a single lattice cell type. In a second embodiment, the chemical composition of the front energy attenuation member model may be consistent throughout the entire model, while the structural makeup may vary between member regions. Specifically, the model may have: (i) a consistent blend of two types of polyurethane, (ii) a first region, which has a first lattice cell type and a first density, and (iii) second region, which has a first lattice cell type and a second density. In this example, the second lattice density may be greater or denser than the first lattice density. Increasing the lattice density, while keeping all other variables (e.g., lattice cell type, material type, etc.) consistent will make the model harder. In other words, it will take more force to compress the model; thus, allowing the model to absorb greater impact forces without becoming fully compressed (otherwise known as bottoming out).

In a third embodiment, the chemical composition of the front energy attenuation member model may be consistent throughout the model, while the structural makeup changes in various regions of the model. Specifically, the front energy attenuation member model may have: between (i) 1 and X different lattice cell types, where X is the number of lattice cells contained within the model, (ii) preferably between 1 and 20 different lattice cell types, and (iii) most preferably between 1 and 10 different lattice cell types. Additionally, the front energy attenuation member model may also have: (i) between 1 and X different lattice densities, where X is the number of lattice cells contained within the model, (ii) preferably between 1 and 30 different lattice densities, and (iii) most preferably between 1 and 15 different lattice densities. Further, the front energy attenuation member may also have: (i) between 1 and X different lattice angles, where X is the number of lattice cells contained within the model, (ii) preferably between 1 and 30 different lattice angles, and (iii) most preferably between 1 and 15 different lattice angles. Specifically, this embodiment may have: (i) a consistent blend of two types of polyurethane, (ii) a first region having a first lattice cell type and a first density, (iii) a second region having a first lattice cell type and a second density, and (iv) a third region having a second lattice cell type and a first density.

In a fourth embodiment, the chemical composition of the front energy attenuation member model may change in various regions of the model, while the structural makeup is consistent throughout the entire model. Specifically, the front energy attenuation member model may have: (i) between 1 and X different chemical compositions, where X is the number of lattice cells contained within the model, (ii) preferably between 1 and 3 different chemical compositions, and most (iii) preferably between 1 and 2 different chemical compositions. In this exemplary embodiment, front energy attenuation member model may have: (i) a first region made from a first ratio of two polyurethanes, (ii) a second region made from a second ratio of one type of two polyurethanes, and (iii) a consistent structural makeup of a single lattice cell type.

In a fifth embodiment, both the structural makeup and the chemical compositions may vary within the front energy attenuation member model. In this exemplary embodiment, the model has: (i) a first region made from a first ratio of two polyurethanes, (ii) a second region made from a second ratio of different polyurethanes, (iii) a third region, which has a first lattice cell type and a first density, (iv) a fourth region, which has a first lattice cell type and a second density, (v) a fifth region, which has a second lattice cell type and a third density, and (vi) a sixth region, which has a third lattice cell type and a first density. It should be understood that while the front energy attenuation member model is discussed above in connection with the five exemplary embodiments, the structural and chemical composition of these five exemplary embodiments may be applied to any one of the energy attenuation members contained within the energy attenuation assembly. Additionally, it should be understood that the selected complete stock helmet170.4,270.4,370.4or selected stock helmet component may include the above disclosed combinations of these structural and chemical compositions. See U.S. patent application Ser. No. 16/543,371.

Once the energy attenuation member models are created in step190.8,290.8,390.8, the player specific helmet models190.12.99,290.12.99,390.12.99are created based upon the CS+CP, CS, and CP helmet models180.28.99,280.10.99,380.28.99and their associated energy attenuation member models190.8.99,290.8.99,390.8.99in step190.12,290.12,390.12. It should be understood that the complete stock helmet models190.12.99,290.12.99,390.12.99may take the form of a finite element model or any other digital model that contains mechanical properties and shape information that can be used later in the digital testing.FIGS. 45A-45Bshow an assembled version of an exemplary 3D energy attenuation member models190.8.99,290.8.99,390.8.99, which are contained within the complete stock helmet model190.12.99,290.12.99,390.12.99.

Referring back toFIG. 44, the complete stock helmet models190.12.99,290.12.99,390.12.99are digitally tested to determine if the impact responses substantially matches the impact responses of the CS+CP, CS, and CP helmet models180.28.99,280.10.99,380.28.99in step190.14,290.14,390.14. The computerized testing system performs this check because the energy attenuation member models may not be able to exactly match the mechanical properties of the energy attenuation members that are contained within the CS+CP, CS, and CP helmet models180.28.99,280.10.99,380.28.99. Thus, this step helps ensure that any changes to the energy attenuation members do not substantially alter the performance of the helmet. To perform this check, both the CS+CP, CS, and CP helmet models180.28.99,280.10.99,380.28.99and the complete stock helmet model190.12.99,290.12.99,390.12.99are digitally tested.FIG. 46shows the digital testing of the complete stock helmet models190.12.99,290.12.99,390.12.99.

Referring back toFIG. 44, if the impact response of the complete stock helmet model190.12.99,290.12.99,390.12.99does not substantially match the CS+CP, CS, and CP helmet models180.28.99,280.10.99,380.28.99in step190.14,290.14,390.14, then the electronic device10determines if it is possible to physically manufacture the CS+CP, CS, and CP helmet models180.28.99,280.10.99,380.28.99in step190.16,290.16,390.16. If it appears to be possible in step190.16,290.16,390.16, then the energy attenuation member models are modified in step190.10,290.10,390.10to better match the performance of the energy attenuation members contained within the CS+CP, CS, and CP helmet models180.28.99,280.10.99,380.28.9. Alternatively, if it is determined that the CS+CP, CS, and CP helmet models180.28.99,280.10.99,380.28.9cannot be manufactured, then the ranges of the variables are altered in step190.18,290.18,390.18and these optimization steps are re-run. In a further alternative, if the impact response of the complete stock helmet model190.12.99,290.12.99,390.12.99substantially matches the CS+CP, CS, and CP helmet models180.28.99,280.10.99,380.28.99in step190.14,290.14,390.14, then the complete stock helmet models are generated and outputted for use in the next steps in designing and manufacturing the helmet1000.

H. Manufacture Player Specific Helmet Model With the Energy Attenuation Assembly

Referring toFIG. 1, the next step is to manufacture player specific helmet based on the player specific helmet model190.12.99,290.12.99,390.12.99. Details about the manufacturing of the player specific helmet195.30.99,295.30.99,395.30.99are described in greater detail inFIG. 47. Referring now toFIG. 47, the first step in this process is inputting the player specific helmet model190.12.99,290.12.99,390.12.99. Next, a method of manufacturing the outer shell is selected in step195.2,295.2,395.2. The selected manufacturing method may include: injection molding, thermoforming, gas-assisted molding, reaction-injection molding, or other similar manufacturing types. It should be understood that the selected manufacturing type should be able to accurately produce the outer shell195.2.99,295.2.99,395.2.99for the prototype helmets195.30.99,295.30.99,395.30.99, whose mechanical and physical properties are similar to the outer shell contained within the complete stock helmet model190.12.99,290.12.99,390.12.99.

Once the outer shells195.2.99,295.2.99,395.2.99are produced in step195.2,295.2,395.2, the designer selects the method of manufacturing the energy attenuation member models in step195.4,295.4,395.4that was previously selected during the design of the energy attenuation member models. One method that may be selected is an additive manufacturing method, which includes: (i) VAT photopolymerization195.4.2.2,295.4.2.2,395.4.2.2, (ii) material jetting195.4.2.4,295.4.2.4,395.4.2.4, (iii) material extrusion195.4.2.6,295.4.2.6,395.4.2.6, (iv) binder jetting195.4.2.8,295.4.2.8,395.4.2.8, or (v) power bed fusion195.4.2.10,295.4.2.10,395.4.2.10. In particular, VAT photopolymerization195.4.2.2,295.4.2.2,395.4.2.2manufacturing technologies include: Stereolithography (“SLA”), Digital Light Processing (“DLP”), Direct UV Processing (“DUP”), or Continuous Liquid Interface Production (“CLIP”). Specifically, SLA can be done through an upside-down approach or a right-side-up approach. In both approaches, a UV laser is directed by at least one mirror towards a vat of liquid photopolymer resin. The UV laser traces one layer of the object (e.g., energy attenuation member model) at a time. This tracing causes the resin to selectively cure. After a layer is traced by the UV laser, the build platform moves to a new location, and the UV laser traces the next layer. For example, this method may be used to manufacture the energy attenuation member models, if they are made from a rigid polyurethane, flexible polyurethane, elastomeric polyurethane, a mixture of any of these polyurethanes, or any similar materials.

Alternatively, a DLP process uses a DLP chip along with a UV light source to project an image of the entire layer through a transparent window and onto the bottom of a vat of liquid photopolymer resin. Similar to SLA, the areas that are exposed to the UV light are cured. Once the resin is cured, the vat of resin tilts to unstick the cured resin from the bottom of the vat. The stepper motor then repositions the build platform to prepare to expose the next layer. The next layer is exposed to the UV light, which cures the next layer of resin. This process is repeated until the entire model is finished. DUP uses a process that is almost identical to DLP, the only difference is that the DLP projector is replaced in DUP with either: (i) an array of UV light emitting diodes (“LEDs”) and a liquid crystal display (“LCD”), wherein the LCD acts as a mask to selectively allow the light from the LEDs to propagate through the LCD to selectively expose the resin or (ii) a UV emitting organic liquid crystal display (“OLED”), where the OLED acts as both the light source and the mask. Like SLA, this process may be used to manufacture the energy attenuation member models, if they are made from a rigid polyurethane, flexible polyurethane, elastomeric polyurethane, a mixture of any of these polyurethanes, or any similar materials.

Similar to DLP and DUP, CLIP uses a UV light source to set the shape of the object (e.g., energy attenuation member model). Unlike DLP and DUP, CLIP uses an oxygen permeable window that creates a dead zone that is positioned between the window and the lowest cured layer of the object. This dead zone helps ensure that the object does not stick to the window and thus the vat does not need to tilt to unstick the object from the window. Once the shape of the object is set by the UV light, the object is fully cured using an external thermal source or UV light. Information about CLIP, materials that can be used in connection with CLIP, and other additive manufacturing information are discussed in J. R. Tumbleston, et al.,Additive manufacturing. Continuous liquid interface production of3D objects. Science 347, 1349-1352 (2015), which is fully incorporated herein by reference for any purpose. Like SLA and DLP, this process may be used to manufacture the energy attenuation member models, if they are made from a rigid polyurethane, flexible polyurethane, elastomeric polyurethane, a mixture of any of these polyurethanes, or any similar materials.

Material jetting195.4.2.4,295.4.2.4,395.4.2.4manufacturing technologies include: PolyJet, Smooth Curvatures Printing, or Multi-Jet Modeling. Specifically, droplets of material are deposited layer by layer to make the object (e.g., energy attenuation member model) and then these droplets are either cured by a light source (e.g., UV light) or are thermally molten materials that then solidify in ambient temperatures. This method has the benefit of being able to print colors within the object; thus, a team's graphics or the player's name may be printed into the energy attenuation assembly. Material extrusion195.4.2.6,295.4.2.6,395.4.2.6manufacturing technologies include: Fused Filament Fabrication (“FFF”) or Fused Deposition Modeling (“FDM”). Specifically, materials are extruded through a nozzle or orifice in tracks or beads, which are then combined into multi-layer models. The FFF method allows for the selective positioning of different materials within the object (e.g., energy attenuation member model). For example, one region of the energy attenuation member model may only contain semi-rigid polyurethane, where another region of the energy attenuation member model contains alternating layers of rigid polyurethane and flexible polyurethane.

Binder jetting195.4.2.8,295.4.2.8,395.4.2.8manufacturing technologies include: 3DP, ExOne, or Voxeljet. Specifically, liquid bonding agents are selectively applied onto thin layers of powdered material to build up parts layer by layer. Additionally, power bed fusion195.4.2.10,295.4.2.10,395.4.2.10manufacturing technologies/products include: selective laser sintering (“SLS”), direct selective laser melting (“SLM”), selective heat sintering (“SHS”), or multi jet fusion (“MJF”). Specifically, powdered materials are selectively consolidated by melting it together using a heat source such as a laser or electron beam. Another method that the designer may select is a manufacturing method that is described within U.S. patent application Ser. No. 15/655,490 in195.4.4,295.4.4,395.4.4or any other method for manufacturing the energy attenuation member models in195.4.6,295.4.6,395.4.6.

Next in step195.6,295.6,395.6, the energy attenuation member models are prepared for manufacturing based upon the selected manufacturing method in step195.4,295.4,395.4. An example of such preparation in connection with CLIP, may include: (i) providing the energy attenuation member model in an Object file (.obj), Stereolithography (.stl), a STEP file (.step), or any other similar file type, (ii) selecting an extent of the model that will be substantially flat and placing that in contact with the lowermost printing surface, (iii) arranging the other models within the printing area, (iv) slicing all models, and (v) reviewing the slices of the models to ensure that they properly manufacture the energy attenuation member models. An example of preparing the energy attenuation member models for manufacturing is shown inFIG. 48.

After the energy attenuation member models are prepared for manufacturing in step195.6,295.6,395.6, the designer physically manufactures the energy attenuation member models in step195.8,295.8,395.8. An example of manufacturing the energy attenuation member models using the CLIP technology is shown inFIGS. 49A-49C. It should also be understood that the selected complete stock helmet170.4can be manufactured using any of the above described methods, as these manufacturing methods were discussed during the formation of these stock helmets170.4. See U.S. patent application Ser. No. 16/543,371, which is incorporated herein by reference. In fact,FIGS. 55A-57B, 60A-61B, 63A-66Bshow exemplary embodiments of the energy attenuation assembly2000of the selected complete stock helmet170.4that was manufactured using CLIP technology.

I. Exemplary Embodiment of a Protective Contact Sports Helmet

FIGS. 50A-54Bare images of the helmet1000that has been selected for the player based on the player's profile120.99,220.99,320.99. The helmet1000includes the shell1012, a facemask or faceguard1200, a chin strap assembly1300, and an energy attenuation assembly2000,3000. The facemask or faceguard1200is attached at upper and lower frontal regions of the shell1012by connectors1210that are removably coupled to the shell by an elongated fastener1215. The faceguard1200comprises an arrangement of elongated and intersecting members and is designed to span a frontal opening in the shell to protect the facial area and chin of the player.

As shown inFIGS. 50A-54B, the shell1012includes an outer shell surface1016featuring complex contours and facets. The shell1012also includes a crown portion1018defining a top region of the helmet1000, a front portion1020generally extending forwardly and downwardly from the crown portion1018, left and right side portions1024extending generally downwardly and laterally from the crown portion1018, and a rear portion1022extending generally rearwardly and downwardly from the crown portion1018. The left and right side portions1024each include an ear flap1026generally positioned to overlie and protect the ear region of the player P when the helmet1000is worn. Each ear flap1026may be provided with an ear hole1030to improve hearing for the wearer. The shell1012is symmetric along a vertical plane dividing the shell1012into left and right halves. When the helmet1000is worn by the player P, this vertical plane is aligned with the midsagittal plane that divides the player P (including his head) into symmetric right and left halves, wherein the midsagittal plane is shown in the NOCSAE standard ND002 for newly manufactured football helmets. Therefore, features shown in Figures as appearing in one half of the shell1012are also present in the other half of the shell1012.

The shell1012also includes a pair of jaw flaps1034, with each jaw flap1034generally extending forwardly from one of the ear flaps1026for protection of the mandible area of the player P. In the illustrated configuration, the jaw flaps1034also include a lower faceguard attachment region1035. An upper faceguard attachment region1036is provided near a peripheral frontal edge1013aof the shell1012and above the ear hole1030. Each attachment region1035,1036includes an aperture1033that receives a fastener extending through the faceguard connector1210to secure the faceguard1200to the shell1012. Preferably, the lower faceguard attachment region1035is recessed inward compared to the adjacent outer surface1034aof the jaw flap1034, and the upper faceguard attachment region1036is recessed inward compared to the adjacent outer surface1026aof the ear flap1026. As shown inFIGS. 51A-51B, there is an angled transition wall1038extending inward from the ear flap outer surface1026A and the jaw flap outer surface1034ato the recessed attachment regions1035,1036. The angled transition wall1038extends from the central frontal edge1013bin the front portion1020rearward and then downward to a lower edge1037of the jaw flap1034. A chin strap securement member1310is positioned rearward of the upper faceguard attachment region1036and is configured to receive a strap member of the chin strap assembly1300.

The helmet1000also includes an integrally raised central band1062that extends from the front shell portion1020across the crown portion1018to the rear shell portion1022. The band1062is defined by a pair of substantially symmetric raised sidewalls or ridges1066that extend upwardly at an angle from the outer shell surface1016. When viewed from the side, the sidewalls1066define a curvilinear path as they extend across the crown portion1018to the rear shell portion1022. As explained in detail below, a front portion1064of the band1062is coincident with an impact attenuation member1042and is positioned a distance above the central frontal edge1013b. Referring toFIG. 52A, the band1062has a width that increases as the band1062extends from the front shell portion1020across the crown portion1018to the rear shell portion1022. As shown inFIG. 53A, a rear portion1068of the band1062is coincident with and merges with a rear raised band1070that extends transversely between the left and right side portions1024of the shell1012. Referring toFIG. 51A, the left sidewall1066aintersects with an upper left sidewall1072aof the transverse band1070, and the right sidewall1066B intersects with an upper right sidewall1072B of the transverse band1070, wherein each of these intersections defines a substantially right angle. A lower transverse sidewall1074extends from the outer shell surface1016along the length of the transverse rear band1070. Similar to the sidewalls1066, the rear band sidewalls1072,1074are sloped, meaning they extend outwardly and upwardly at an angle from the outer shell surface1016. Referring toFIG. 51A, a lower channel1080extends transversely below the raised rear band1070and above a lower rear shell edge1081.

As shown in the Figures, the helmet1000further includes numerous vent openings that are configured to facilitate circulation within the helmet1000when it is worn by the player P. A first pair of vent openings1084are formed in the crown portion1018, wherein the left vent opening1084A is substantially adjacent the left side wall1066A and the right vent opening1084B is substantially adjacent to the right sidewall1066B. The left and right vent openings1084A,B have a longitudinal centerline that is generally aligned with an adjacent extent of the respective sidewall1066A,B. A second pair of vent openings1086are formed in the rear shell portion1022, wherein the left vent opening1086A is substantially adjacent to the left sidewall1066A and left band sidewall1072A, and the right vent opening1086B is substantially adjacent the right sidewall1066B and right band sidewall1072B. The left and right vent openings1086A,B have a longitudinal centerline that is generally aligned with the respective sidewall1066A,B. In this manner, the left first and second vent openings1084A,1086A are substantially aligned along the left sidewall1066A, and the right first and second vent openings1084A,1086A are substantially aligned along the right sidewall1066B.

Referring toFIG. 53A, a third pair of vent openings1088are formed in the rear shell portion1022below the rear raised band1070, wherein the left vent opening1088A is positioned adjacent a left ridge1087A formed by an angled side wall1085A and the right vent opening1088B is positioned adjacent a right ridge1087B formed by an angled sidewall1085B. The third vent openings1088A,B have a longitudinal centerline that is oriented substantially perpendicular to the raised central band1062, and that would intersect, if extended, the ear opening1030. A fourth pair of vent openings1090are formed in the front shell portion1020, wherein the left vent opening1090A is positioned adjacent to a left frontal ridge1092A and the right vent opening1092A is positioned adjacent a right frontal ridge1092B. The frontal ridges1097A,B are located between the front shell portion1020and the side portion1024and thus generally overlie the temple region of the player P when the helmet1000is worn. Referring toFIGS. 63A-63B, the frontal ridges1097A,B are also formed from an angled sidewall and include an upper inclined segment1089A,B, a declining intermediate segment1091A,B, and a lower segment1093A,B that extends rearward at a slight angle towards the side shell portion1024. The fourth vent openings1090A,B have a major component1095A,B, and a minor component1097A,B wherein the major component1095A,B is aligned with the upper segment1089A,B and the intermediate segment1091A,B, and the minor component1097A,B has a width that tapers as it extends along the lower segment1093A,B. The outer shell surface1016adjacent and rearward of the vent openings1090A,B is recessed relative to the outer shell surface16adjacent and forward of the frontal ridges92A,B. The first, second, third and fourth vent openings1084A,B,1086A,B,1088A,B and1090A,B are cooperatively positioned with voids in the energy attenuation assembly2000to facilitate the flow of air through the helmet1000.

A front portion1064of the helmet1000, the central band1062has a width of at least 2.0 inches, and preferably at least 2.25 inches, and most preferably at least 2.5 inches and less than 3.5 inches. Proximate the juncture of the raised central band1062and the raised rear band1070, the raised central band1062has a width of at least 4.0 inches, and preferably at least 4.25 inches, and most preferably at least 4.5 inches and less than 5.0 inches. At this same juncture, the raised band1070has a height of at least 1.25 inch, and preferably at least 1.5 inches, and most preferably at least 1.5 inch and less than 2.0 inches. At the region where the terminal ends1070A of the rear raised band1070merges flush with the outer shell surface16, slightly rearward of the ear opening1030(seeFIG. 51A), the terminal end1070aof the raised band1070has a height of at least 0.75 inches, and preferably at least 1.0 inch and less than 1.75 inch. Accordingly, the height of the raised rear band1070tapers as each lateral band segment1070bextends from the raised central band1062forward towards the respective ear flap1026. Because the raised central band1062and the raised rear band1070are formed as corrugations in the shell1012, the foregoing dimensions contribute to increasing the mechanical properties of the crown portion1018and the rear shell portion1022, namely the structural modulus (Es), of these portions1018,1022. The structural modulus provides a stiffness value of a respective portion of the helmet1000based upon its geometry. A higher structural modulus value corresponds to increased stiffness of that portion of the helmet1000.

The helmet shell1012also includes an impact attenuation system1014, which is comprised of the impact attenuation member1042which adjusts how the portion of the helmet1000, including the member, 42 responds to impact forces compared to adjacent portions of the helmet1000lacking the member1042. The impact attenuation member1042is formed by altering at least one portion of the shell1012wherein that alteration changes the configuration of the shell1012and its local response to impact forces. For example, in the illustrated configuration, the impact attenuation member1042includes an internal cantilevered segment or flap1044formed in the front shell portion1020. Compared to the adjacent portions of the shell1012that lack the cantilevered segment1044, the front shell portion1020has a lower structural modulus (Es) which improves the attenuation of energy associated with impacts to at least the front shell portion20. Thus, the configuration of the helmet1000provides localized structural modulus values for different portions of the helmet1000.

As shown in the Figures, the illustrated cantilevered segment1044is formed by removing material from the shell1012to define a multi-segment gap or opening1046, which partially defines a boundary of the cantilevered segment1044. Unlike conventional impact force management techniques that involve adding material to a helmet, the impact attenuation system1014involves the strategic removal of material from the helmet1000to integrally form the cantilevered segment1044in the shell1012. The cantilevered segment1044depends downward from an upper extent of the front shell portion1020near the interface between the front portion1020and the crown portion1018. The cantilevered segment1044includes a base1054and a distal free end58and approximates the behavior of a living hinge when a substantially frontal impact is received by the front shell portion20. The lowermost edge of the free end1058is positioned approximately 1.5-2.5 inches, preferably 2.0 inches from the central frontal edge13b, wherein the lower shell portion1020aof the front shell portion1020is therebetween.

As shown inFIGS. 50B, 52A, the opening1046and the cantilevered segment1044are generally U-shaped with an upward orientation, meaning that they are oriented upwards towards the crown portion1018. The opening1046has a complex geometry with a number of distinct segments. A first generally vertical right segment1046A extends downward and outward from a right endpoint1048A towards the right side of the front shell portion1020. A second generally vertical right segment1046B extends downward and inward from the first right segment1046A to a generally lateral segment1049. Similarly, a first generally vertical left segment1047A extends downward and outward from a left endpoint1048B towards the left side of the front shell portion1020. A second generally vertical left segment1047B extends downward and inward from the first left segment1047A to the lateral segment49. The lateral segment49extends between the second right and left segments1046B,1047B. The lowermost extent of the lower, second right and left segments1046B,1047B is positioned approximately 1.5-2.5 inches, preferably 2.0 inches from the central frontal edge1013B. In the illustrated embodiment, the lateral segment49forms an obtuse angle with the respective second right and left segments1046B,1047B, and the first right and left segments1046A,1047A form an obtuse angle with the respective second right and left segments1046B,1047B. Also, the left and right endpoints1048A,B have a substantially circular configuration with a width that exceeds the width of the opening46. Although the illustrated first and second segments1046A,B,1047A,B and the lateral segment1049are substantially linear, these segments can be configured as curvilinear or a combination of curvilinear and straight segments. Furthermore, the opening1046may be formed by more or less than the five segments1046A,B,1047A,B and1049, as shown, for example, in the alternative embodiments discussed below.

In the embodiment Figures, the raised central band1062and its sidewalls1066A,B extend upward from the distal end1058across an intermediate portion1059and then beyond the base1054of the cantilevered segment1044. In this manner, the leading edges of the raised central band1062and the sidewalls1066A,B taper into and are flush with the distal end1058proximate the lateral segment1049. Alternatively, the leading edges of the raised central band1062and the sidewalls1066A,B are positioned above the distal end of1058and closer to the base1054. In another alternative, the leading edge of the raised central band1062and the sidewalls1066A,B are positioned above the base1054, whereby the raised central band1062is external to the cantilevered segment44. As shown inFIG. 54A, the shell1012also includes an inner central bead1019formed from material added to the shell1012, wherein the bead1019extends along the inner shell surface1017from the crown portion1018to the cantilevered segment1044. The bead1019has a rounded nose1019A that extends downward past the base1054to the intermediate portion1059and towards the distal end1058. Preferably, a major extent of the cantilevered segment1044has the same wall thickness as the other portions of the front shell portion1020and the crown portion1018. For example, the intermediate portion1059and the distal end1058of the cantilevered segment1044, the front shell portion1020and the crown portion1018have a nominal wall thickness of 0.125-inch±0.005 inches. In addition, bosses1053A,B are formed on the inner shell surface1017around the eyelets1048A,B to increase the durability of this region of the shell1012and cantilevered segment1044.

As shown inFIG. 51A, chin strap securement member1310is positioned rearward of the upper faceguard attachment region1036and is configured to receive an upper strap member1312of the chin strap assembly1300. A multi-adjustable chin strap securement member1320, which is positioned rearward of the lower faceguard attachment region1035and along a lower side shell edge1013C, is configured to receive a lower strap member1314of the chin strap assembly1300. The multi-adjustable chin strap securement member1320is received by a receptacle1325formed in a lower portion of the shell1012. In the use position shown inFIG. 1, the upper strap member1312extends between the upper peripheral portion1220of the faceguard1200and the upper attachment region1036. More specifically, the upper strap member1312extends through a gap or clearance formed between the outer surface of the upper attachment region1036and the inner surface of the upper peripheral faceguard portion1220. The upper strap member1312can engage the second downward segment1058C of the transition wall58.

J. Exemplary Embodiment of a Stock Energy Attenuation Assembly for Use in a Protective Contact Sports Helmet

FIGS. 55A-57B, 60A-61B, 63A-66Bshow an assembled stock energy attenuation assembly2000for use in a protective contact sports helmet, such as the football helmet1000, or a hockey helmet or lacrosse helmet. The stock energy attenuation assembly2000is comprised of: (i) a front energy attenuation member2010, (ii) a crown energy attenuation member2050, (iii) left and right energy attenuation members2100A,B, (iv) left and right jaw energy attenuation members2150A,B, (v) a rear energy attenuation member2200, and (vi) occipital energy attenuation member2250. As shown in these figures and described below, the energy attenuation members contained within the stock energy attenuation assembly2000use different lattice cells, different lattice densities, different lattice angles, and different materials. The use of these varying structural designs and chemical compositions allows the designer to tune the lattice components in order to manage impact energies and forces, such as linear and rotational forces.

While additional details will be provided below, the exemplary embodiment of the stock energy attenuation assembly2000contains at least ten different member regions. The member regions are split amongst the energy attenuation assembly2000, as follows: (i) two regions within the front energy attenuation member2010, (ii) one region within the crown energy attenuation member2050, (iii) two regions within the left and right energy attenuation members2100A,B, (iv) two regions within the left and right jaw energy attenuation members2150A,B, (v) one region within the rear energy attenuation member2200, and (vi) two regions within the occipital energy attenuation member2250. The exemplary embodiment of the stock energy attenuation assembly2000also includes at least five different strut based lattice cell types and at least three different surface based lattice cell types. For example, the front energy attenuation member2010includes a gyroid lattice cell2030, while the left and right energy attenuation members2100A,B include an FRD lattice cell. Further, the exemplary embodiment of the stock energy attenuation assembly2000includes multiple different lattice densities. These differences can be seen by visually comparing the crown energy attenuation member2050with the rear energy attenuation member2200. It should be understood that in different embodiments, the energy attenuation assembly2000may have different number of member regions, types of lattice cells, and lattice density values. For example, the energy attenuation assembly2000may have between: (i) 1 and X different lattice cell types, where X is the number of lattice cells contained within the assembly2000, (ii) 1 and Y different lattice member thicknesses, where Y is the number of lattice cells contained within the assembly2000, (iii)1and Z different lattice densities, where Z is the number of lattice cells contained within the assembly2000, and (iv) 1 and U different member regions, where U is the number of lattice cells contained within the assembly2000. In one exemplary embodiment, the lattice density of the front energy attenuation member may range between 4 to 17 pounds per cubic foot and preferably between 4 to 9 pounds per cubic foot.

In addition to the above described structural differences, the energy attenuation assembly2000also includes different chemical compositions. In particular, the exemplary embodiment of the stock energy attenuation assembly2000is made from two different materials. The front energy attenuation member2010is made from a first blend or ratio of rigid polyurethane and flexible polyurethane, while all other energy attenuation members2050,2100A,B,2150A,B,2200,2250are made from a second blend or ratio of rigid polyurethane and flexible polyurethane. It should be understood that in different embodiments, the energy attenuation assembly2000may be made from: between (i) 1 and X different chemical compositions, where X is the number of lattice cells contained within the assembly2000, (ii) preferably between 1 and 20 different chemical compositions, and (iii) most preferably between 1 and 3 different chemical compositions.

As shown inFIGS. 55A-57Band, the front energy attenuation member2010has a curvilinear configuration that corresponds to the curvature of the inner surface1017of the shell1012and the cantilevered segment1044. The front energy attenuation member2010also has: (i) a recessed central region2421that facilitates engagement of the crown energy attenuation member2050. When the helmet1000is worn by the player, the front energy attenuation member2010engages the player's frontal bone or forehead while extending laterally between the player's temple regions and extending vertically from the player's brow line BL across the player's forehead. The front energy attenuation member2010also includes means2006for securing or coupling, such as hook and loop fasteners sold under VELCRO® or a snap connector, the energy attenuation member2010to the inner shell surface1017. As shown inFIG. 56A, the front energy attenuation member2010also includes a surface or panel that allows for indicia2012, such as the manufacturer of the helmet1000, a team name, a player's name, and/or the month and year the member was manufactured. Further, the front energy attenuation member2010includes a surface or panel that allows for a tracking device2014, such as a bar code or QR code. In other embodiments, the tracking device2014may be RFID chips or other electronic chips that can be scanned from the exterior of the helmet and used for tracking purposes.

In this exemplary embodiment, the front energy attenuation member2010is a non-homogeneous member, as it includes approximately five different layers or regions. The first layer of2028that is positioned adjacent to the curvature of the inner surface1017of the helmet shell1012is an exterior open skin2020. First, this exterior skin2020is open and not closed because there are holes2022formed therethrough. The use of this exterior open skin2020is desirable because it provides a substantially smooth surface, which cannot be provided by the adjacent surface based lattice cell. In this exemplary embodiment, this exterior skin can have a thickness that is between 0.5 mm and 3 mm, and preferably 1 mm. Adjacent to the exterior open skin2020, is the energy management region2024of the front energy attenuation member2010(shown inFIG. 59A). Overall, this energy management region2024is designed to absorb a majority of the linear and rotational energies that are translated through the helmet shell1012to the front energy attenuation member2010. This energy management region2024includes a surface based lattice cell, which in this exemplary embodiment is a gyroid lattice cell2030. Based on the safety regulations (e.g., promulgated by NOCSAE) and tests that are utilized by third party testing organizations (e.g., NFL, Virginia Tech, etc.), it is desirable to utilize a surface based lattice cell type over a strut based lattice cell type for the energy management region2024. In other words, the surface based lattice cell types perform better than the strut based lattice cell types in the energy management region2024in light of the current requirements. In particular, a gyroid lattice cell2030is used within this energy management region2024. It should be understood that in different embodiments, in connection with different testing requirements, or if different materials are utilized, strut based lattice cell types or different surface lattice cells may outperform the gyroid lattice cell2030. As such, the use of any type of lattice cell, any density, any angle is contemplated by this disclosure.

An interior open skin2032is positioned adjacent to the energy management region2024. Thus, the energy management region in2024is positioned between exterior open skin2020and the interior open skin2032. The interior open skin2032is also positioned adjacent to the fitting region2026(shown inFIG. 57C). This interior open skin2032acts as a divider between the fitting region2026and the energy management region2024, which may allow for the presence of desirable boundary conditions. This fitting region2026includes a strut based lattice cell2034, which provides desirable fitting characteristics. It should be understood that in different embodiments or if different materials are utilized, surface based lattice cell types or different strut based lattice cells may outperform the current strut based lattice cell. As such, the use of any type of lattice cell, any density, any angle is contemplated by this disclosure.

Finally, a closed skin2202is positioned adjacent to the fitting region2026(seeFIGS. 57A-57B). The closed skin2202creates a substantially smooth surface that is designed to come into contact with the player's forehead. The skin2202is integrally formed as a part of the member2010and as such the lattice cells on the side of the member2010blend into the skin2202as the lattice cells approach the inner surface of the member2010. This blending of the lattice cells into the skin2202starts to occur prior to the shoulders2018of the member2010. Utilizing the skin and starting the skin2202in this location helps prevent the lattice cells from imprinting their pattern on the player's head. In one embodiment, the skin2202has a thickness that is greater than 0.1 mm; however, it should be understood that the thickness of this skin2202may be changed. It should also be understood that the skin2202may extend around the side regions of the member2010or may completely encase the member2010(e.g., where the member has a substantially smooth surface on the outside of all sides of the member2010).

FIGS. 58A-59Bshow compressions curves for two embodiments of the front energy attenuation member2010, wherein the percent the member2010is compressed is shown on the X-axis and the pressure (psi) it takes to compress the member2010to that extent is shown on the Y-Axis. In other words, this graphs58A and59B show how much pressure must be exerted on this two embodiments of the member2010to compress the embodiments of the member2010from 0% compression to 80% of its original thickness. Based on this the graphs shown inFIGS. 58A-58B, which are based on a first embodiment of the front energy attenuation member2010, compressing the member to 15% of its total thickness requires about 10 psi, compressing the member to 25% of its total thickness requires about 21 psi, and compressing the member to 60% of its total thickness requires about 80 psi. From the above disclosure, it should be understood that both the structural makeup (e.g., lattice cell types, lattice densities, lattice angles) and the chemical compositions may vary depending on whether the front energy attenuation member2010is designed for: (i) all players, (ii) a specific position (e.g., lineman), (iii) a specific playing level (e.g., NCAA players), or (iv) a position and playing level design (e.g., varsity quarterback).

As shown inFIGS. 55A-55E and 60A-60C, the crown energy attenuation member2050has a curvilinear configuration that corresponds to the curvature of the inner surface1017of the helmet shell1012. The crown energy attenuation member2050has a region that is designed to engage with the front energy attenuation member2010. Like the front energy attenuation member2010, the crown energy attenuation member2050includes: (i) means for securing or coupling2006, such as hook and loop fasteners sold under VELCRO® or a snap connector, the members2050to the inner shell surface1017, (ii) indicia2012, and (iii) tracking device2014. The crown energy attenuation member2050includes a strut based lattice cell that extends throughout the entire member and creates a substantially homogeneous member. This member2050can utilize a single strut based lattice cell throughout the member2050because the compression curve for the energy management region does not vary enough to warrant the inclusion of an additional lattice cell type. Similarly, this member2050does not include an exterior open skin because, unlike a surface lattice cell, a strut based lattice cell can terminate at a surface without providing a non-smooth outer surface. In one exemplary embodiment, the lattice density of the crown energy attenuation member2050may range between 3 to 7 pounds per cubic foot. It should be understood that crown energy attenuation member2050has the same flexibility in its structural makeup and chemical composition as discussed above and as such its structural makeup and/or the chemical composition may differ from: (i) all other members within the energy attenuation assembly2000, (ii) a percentage of the members within the energy attenuation assembly2000, or (iii) none of the members within the energy attenuation assembly2000.

As shown inFIGS. 55A-57B, 61A-61B, the left and right energy attenuation members2100A,B have a curvilinear configuration that corresponds to the curvature of the inner surface1017of an extent of the side shell portions1024. The left and right energy attenuation members2100A,B have regions that are designed to engage with the front energy attenuation member2010. Like the front energy attenuation member2010, the left and right energy attenuation members2100A,B include: (i) means for securing or coupling2006, such as hook and loop fasteners sold under VELCRO® or a snap connector, the members2150A,B to the inner shell surface1017, (ii) indicia2012, and (iii) tracking device2014. Also, in this exemplary embodiment, the left and right energy attenuation members2100A,B is non-homogeneous, as they include approximately five different layers. The first layer that is positioned adjacent to the curvature of the inner surface1017of the helmet shell1012is an exterior open skin2020. The use of this exterior open skin is desirable because it provides a substantially smooth surface, which cannot be provided by the adjacent surface based lattice cell. In this exemplary embodiment, this exterior skin can have a thickness that is between 0.5 mm and 3 mm, and preferably 1 mm.

Adjacent to the exterior open skin2020is the energy management region2024of the left and right energy attenuation members2100A,B. Overall, this energy management region2024is designed to absorb a majority of the linear and rotational energies that are translated through the helmet shell1012. This energy management region2024includes a surface based lattice cell, which in this exemplary embodiment is a FRD. An interior open skin is positioned adjacent to the energy management region2024. Thus, the energy management region2024is positioned between exterior open skin2020and the interior open skin. The interior open skin is also positioned adjacent to the fitting region2026. This interior open skin may act as a divider between the fitting region2026and the energy management region2024, which may allow for the presence of desirable boundary conditions. This fitting region2026includes a strut based lattice cell, which provides desirable fitting characteristics. It should be understood that in different embodiments or if different materials are utilized, surface based lattice cell types or different strut based lattice cells may outperform the current strut based lattice cell. As such, the use of any type of lattice cell, any density, any angle is contemplated by this disclosure. In one exemplary embodiment, the lattice density of the left and right energy attenuation members2100A,B may range between 3 to 7 pounds per cubic foot. Additionally, it should be understood that the structural makeup and/or the chemical compositions of the left and right energy attenuation members2100A,B may differ from: (i) all other members within the energy attenuation assembly2000, (ii) a percentage of the members within the energy attenuation assembly2000, or (iii) none of the members within the energy attenuation assembly2000.

Finally, a closed skin2202is positioned adjacent to the fitting region2026(seeFIG. 61A). The closed skin2202creates a substantially smooth surface that is designed to come into contact with the player's forehead. The skin2202is integrally formed as a part of the members2100A,B and as such the lattice cells on the side of the members2100A,B blend into the skin2202as the lattice cells approach the inner surface of the member2100A,B. This blending of the lattice cells into the skin2202starts to occur prior to the shoulders2018of the members2100A,B. Utilizing the skin and starting the skin2202in this location helps prevent the lattice cells from imprinting their pattern on the player's head. In one embodiment, the skin2202is between 0.1 mm and 10 mm; however, it should be understood that the thickness of this skin2202may be changed. It should also be understood that the skin2202may extend around the side regions of the member2100A,B or may completely encase the member2100A,B (e.g., where the member has a substantially smooth surface on the outside of all sides of the member2100A,B).

FIGS. 62A-62Bshow compressions curves for the left and right energy attenuation members2100A,B, wherein the percent the members2100A,B is compressed is shown on the X-axis and the pressure (psi) it takes to compress the members2100A,B to that extent is shown on the Y-Axis. In other words, this graph shows how much pressure must be exerted on this member2100A,B to compress the member2010from 0% compression to 80% of its original thickness. Based on this graph, compressing the member2100A,B to 25% of its total thickness requires about 12 psi and compressing the member to 50% of its total thickness requires about 56 psi. In this exemplary embodiment, the left and right energy attenuation members2100A,B require almost 50% less force to compress the members to 25% of their thickness in comparison with the first embodiment of the front energy attenuation member2010. From the above disclosure, it should be understood that both the structural makeup (e.g., lattice cell types, lattice densities, lattice angles) and the chemical compositions may vary depending on whether the front energy attenuation member2010is designed for: (i) all players, (ii) a specific position (e.g., lineman), (iii) a specific playing level (e.g., NCAA players), or (iv) a position and playing level design (e.g., varsity quarterback).

As shown inFIGS. 55A-57B, 63A-63B, the left and right jaw energy attenuation members2150A,B have a curvilinear configuration that corresponds to the curvature of the inner surface1017of an extent of the ear flap1026portions of the shell1012. The left and right jaw energy attenuation members2150A,B are configured to engage with the left and right energy attenuation members2100A,B. Like the front energy attenuation member2010, the left and right jaw energy attenuation members2150A,B also includes: (i) means for securing or coupling2006, such as hook and loop fasteners sold under VELCRO® or a snap connector, the energy attenuation members2150A,B to the inner shell surface1017, (ii) indicia2012, and (iii) tracking device2014. Also, in this exemplary embodiment, the left and right jaw energy attenuation members2150A,B are non-homogeneous members, which include approximately four different layers. The first layer is an energy management region of the left and right jaw energy attenuation members2150A,B. Overall, this energy management region2024is designed to absorb a majority of the linear and rotational energies that are translated through the helmet shell1012. This energy management region2024includes a strut based lattice cell. An interior open skin is positioned adjacent to the energy management region2024and a fitting region2026. This interior open skin may act as a divider between the fitting region2026and the energy management region2024, which may allow for the presence of desirable boundary conditions. This fitting region2026includes a strut based lattice cell, which provides desirable fitting characteristics. It should be understood that in different embodiments or if different materials are utilized, surface based lattice cell types or different strut based lattice cells may outperform the current strut based lattice cell. As such, the use of any type of lattice cell, any density, any angle is contemplated by this disclosure. In one exemplary embodiment, the lattice density of the left and right jaw energy attenuation members2150A,B may range between 3 to 7 pounds per cubic foot. Additionally, it should be understood that the structural makeup and/or the chemical compositions of the left and right jaw energy attenuation members2150A,B may differ from: (i) all other members within the energy attenuation assembly2000, (ii) a percentage of the members within the energy attenuation assembly2000, or (iii) none of the members within the energy attenuation assembly2000.

Finally, a closed skin2202is positioned adjacent to the fitting region2026(seeFIGS. 63A-63B). The closed skin2202creates a substantially smooth surface that is designed to come into contact with the player's forehead. The skin2202is integrally formed as a part of the members2150A,B and as such the lattice cells on the side of the members2150A,B blend into the skin2202as the lattice cells approach the inner surface of the members2150A,B. This blending of the lattice cells into the skin2202starts to occur prior to the shoulders2018of the members2150A,B. Utilizing the skin and starting the skin2202in this location helps prevent the lattice cells from imprinting their pattern on the player's head. In one embodiment, the skin2202is between 0.1 mm and 5 mm; however, it should be understood that the thickness of this skin2202may be changed. It should also be understood that the skin2150A,B may extend around the side regions of the members2150A,B or may completely encase the members2150A,B (e.g., where the member has a substantially smooth surface on the outside of all sides of the members2150A,B).

As shown inFIGS. 55A-55E and 64A-64C, the rear energy attenuation member2200has a curvilinear configuration that corresponds to the curvature of the inner surface1017of the helmet shell1012. Like the front energy attenuation member2010, the rear energy attenuation member2200includes: (i) means for securing or coupling2006, such as hook and loop fasteners sold under VELCRO® or a snap connector, the members2050to the inner shell surface1017, (ii) indicia2012, and (iii) tracking device2014. The rear energy attenuation member2200includes a strut based lattice cell that extends throughout the entire member and creates a substantially homogeneous member. This member2200can utilize a single strut based lattice cell throughout the member2200because the compression curve for the energy management region does not vary enough to warrant the inclusion of an additional lattice cell type. Although both the crown energy attenuation member2050and the rear energy attenuation member2200include a single strut based lattice, these lattice cell types are different and the densities of these cell types are different. Similarly, this member2200does not include an exterior open skin because, unlike a surface lattice cell, a strut based lattice cell can terminate at a surface without providing a non-smooth outer surface. In one exemplary embodiment, the lattice density of the rear energy attenuation member2200may range between 3 to 7 pounds per cubic foot. It should be understood that rear energy attenuation member2200has the same flexibility in its structural makeup and chemical composition as discussed above and as such its structural makeup and/or the chemical composition may differ from: (i) all other members within the energy attenuation assembly2000, (ii) a percentage of the members within the energy attenuation assembly2000, or (iii) none of the members within the energy attenuation assembly2000.

As shown inFIGS. 55A-57B and 65A-65C, the occipital energy attenuation member2250has a curvilinear configuration that corresponds to the curvature of the inner surface1017of an extent of the rear portion of the shell1012. Like the front energy attenuation member2010, the occipital energy attenuation member2250also includes: (i) means for securing or coupling2006, such as hook and loop fasteners sold under VELCRO® or a snap connector, the energy attenuation member2200to the inner shell surface1017, (ii) indicia2012, and (iii) tracking device2014. Also, in this exemplary embodiment, the occipital energy attenuation member2250is non-homogeneous, as they include approximately four different layers. The first layer that is positioned adjacent to the curvature of the inner surface1017of the helmet shell1012is an energy management region2024of the occipital energy attenuation member2250. Overall, this energy management region2024is designed to absorb a majority of the linear and rotational energies that are translated through the helmet shell1012. This energy management region2024includes a strut based lattice cell. An interior open skin is positioned adjacent to the energy management region2024and a fitting region2026. This interior open skin may act as a divider between the fitting region2026and the energy management region2024, which may allow for the presence of desirable boundary conditions. This fitting region2026includes a surface based lattice cell, which provides desirable fitting characteristics. It should be understood that in different embodiments or if different materials are utilized, surface based lattice cell types or different strut based lattice cells may outperform the current strut based lattice cell. As such, the use of any type of lattice cell, any density, any angle is contemplated by this disclosure. In one exemplary embodiment, the lattice density of the occipital energy attenuation member2250may range between 3 to 7 pounds per cubic foot. Additionally, it should be understood that the structural makeup and/or the chemical compositions of the occipital energy attenuation member2250may differ from: (i) all other members within the energy attenuation assembly2000, (ii) a percentage of the members within the energy attenuation assembly2000, or (iii) none of the members within the energy attenuation assembly2000.

Finally, a closed skin2202is positioned adjacent to the fitting region2026(seeFIG. 65A). The closed skin2202creates a substantially smooth surface that is designed to come into contact with the player's forehead. The skin2202is integrally formed as a part of the member2250and as such the lattice cells on the side of the member2250blend into the skin2202as the lattice cells approach the inner surface of the member2250. This blending of the lattice cells into the skin2202starts to occur prior to the shoulders2018of the member2250. Utilizing the skin and starting the skin2202in this location helps prevent the lattice cells from imprinting their pattern on the player's head. In one embodiment, the thickness of the skin2202is greater than 0.1 mm. It should also be understood that the skin2202may extend around the side regions of the member2250or may completely encase the member2250(e.g., where the member has a substantially smooth surface on the outside of all sides of the member2250).

K. Exemplary Embodiment of a Custom Energy Attenuation Assembly for Use in a Protective Contact Sports Helmet

FIGS. 67-73, 74A, 75Ashow an assembled stock energy attenuation assembly3000for use in a protective contact sports helmet, such as the football helmet1000, or a hockey helmet or lacrosse helmet. The custom energy attenuation assembly3000is comprised of: (i) a front energy attenuation member3010, (ii) a crown energy attenuation member3050, (iii) left and right energy attenuation members3100A,B, (iv) left and right jaw energy attenuation members3150A,B, and (v) a rear combination energy attenuation member3200. As shown inFIG. 72B, the custom energy attenuation assembly3000may include at least one badge, which may have indicia such as a player's name, jersey number and/or signature, and/or a name, slogan or images of an entity such as a company. In particular, a player identification badge3002, may be disposed on the rear combination energy attenuation member3200while a protective sports helmet identification badge3004, identifying the helmet model and/or manufacturer, may be placed on the crown energy attenuation member3050. The identification badge3002may also include a reproduction of the player's actual signature. In addition to enhancing the aesthetic appeal and desirability, the identification badge3002is useful in helping a player quickly ascertain his or her helmet from among a group of similarly-appearing helmets.

The shape, structural design, and material composition of the front energy attenuation member3010, the crown energy attenuation member3050, the left and right energy attenuation members3100A,B, the left and right jaw energy attenuation members3150A,B, and the rear combination energy attenuation member3200, are discussed in greater detail below. However, it should at least be understood that each member contained within the energy attenuation assembly3000may have different impact responses when compared to other members within the energy attenuation assembly3000. In fact, even different regions within the same member may have different impact responses when compared to one another. These differing impact responses may be utilized by the designer to adjust how the energy attenuation assembly3000and in turn the helmet1000responds to impact forces. As discussed in greater detail below, these differing impact responses may be obtained by varying the structural makeup and/or the chemical composition of the energy attenuation assembly3000.

While additional details will be provided below, the exemplary embodiment of the stock energy attenuation assembly3000contains at least nine different member regions. The member regions are split amongst the energy attenuation assembly3000, as follows: (i) two regions within the front energy attenuation member3010, (ii) one region within the crown energy attenuation member3050, (iii) two regions within the left and right energy attenuation members3100A,B, (iv) two regions within the left and right jaw energy attenuation members3150A,B, and (v) two regions within the rear combination energy attenuation member3200. The exemplary embodiment of the custom energy attenuation assembly3000also includes at least six different strut based lattice cell types. For example, the front energy attenuation member3010lattice cell type is different than the lattice cell type that is contained within the crown energy attenuation member3050. Further, the exemplary embodiment of the custom energy attenuation assembly3000includes multiple different lattice densities. These differences can be seen by visually comparing the crown energy attenuation member3050with the rear energy attenuation member3200. It should be understood that in different embodiments, the energy attenuation assembly3000may have different number of member regions, types of lattice cells, and lattice density values. For example, the energy attenuation assembly3000may have between: (i) 1 and X different lattice cell types, where X is the number of lattice cells contained within the assembly3000, (ii) 1 and Y different lattice member thicknesses, where Y is the number of lattice cells contained within the assembly3000, (iii) 1 and Z different lattice densities, where Z is the number of lattice cells contained within the assembly3000, and (iv) 1 and U different member regions, where U is the number of lattice cells contained within the assembly3000. In one exemplary embodiment, the lattice density of the front energy attenuation member may range between 3 to 17 pounds per cubic foot and preferably between 4 to 9 pounds per cubic foot.

As shown inFIGS. 67-68C, the front energy attenuation member3010has a curvilinear configuration that corresponds to the curvature of the inner surface1017of the shell1012and the cantilevered segment1044. The front energy attenuation member3010also has: (i) a recessed central region3421that facilitates engagement of the crown energy attenuation member3050and (ii) peripheral recesses3422that facilitates engagement of the energy attenuation member3010with the left and right energy attenuation members3100A,B. When the helmet1000is worn by the player, the front energy attenuation member3010engages the player's frontal bone or forehead while extending laterally between the player's temple regions and extending vertically from the player's brow line across the player's forehead. The front energy attenuation member3010also includes means3006for securing or coupling, such as hook and loop fasteners sold under VELCRO® or a snap connector, the energy attenuation member3010to the inner shell surface1017. As shown inFIG. 68A, the front energy attenuation member3010also includes a surface or panel that allows for indicia3012, such as the manufacturer of the helmet1000, a team name, a player's name, and/or the month and year the member was manufactured. Further, the front energy attenuation member3010includes a surface or panel that allows for tracking device3014, such as a bar code or QR code. In other embodiments, the tracking device3014may be RFID chips or other electronic chips that can be scanned from the exterior of the helmet and used for tracking purposes.

The front energy attenuation member3010includes two different regions, a fitting region3024and an energy management region2026. Both of these regions3024,3026include strut based lattices; however, these strut based lattices are different from one another. From the above disclosure, it should be understood that both the structural makeup (e.g., lattice cell types, geometry of each lattice cell type, lattice densities, lattice angles) and the chemical compositions may vary depending on whether the front energy attenuation member3010is designed for: (i) a group of all players, (ii) a specific position (e.g., lineman), (iii) a specific playing level (e.g., NCAA players), or (iv) a position and playing level design (e.g., varsity quarterback). For example,FIG. 40shows different possible designs for the front energy attenuation member3010, where one design may be for a youth lineman, while another is designed for a varsity cornerback.

As shown inFIGS. 67-73, that each member3010,3050,3100,3150,3200has an exterior closed skin3202that creates a substantially smooth surface. The lattice cells on the sides of the member3200blends into the skin3202as the lattice cells approach the inner surface of the member3010,3050,3100,3150,3200. This skin3202creates a substantially smooth surface that helps prevent the lattice cells from imprinting their pattern on the player's head. Also, this skin3202does not hinder the compression of the lattice cells when a force is applied to the member3200. In one embodiment, the skin3202may have a thickness that is greater than 0.1 mm; however, it should be understood that the thickness of this skin3202may be changed. Further, like other components of the member, the thickness of this skin3202may alter the mechanical characteristics (e.g., impact absorption) of the member3200. It should be understood that in some embodiments the skin3202may be external to the member3200and/or removable. It should also be understood that the skin3202may extend around the side regions of the member3200or may completely encase the member3200(e.g., where the member has a substantially smooth surface on the outside of all sides of the member3010,3050,3100,3150,3200, while the lattice cells are positioned within the skin3202).

As shown inFIGS. 67 and 70A-70B, the left and right energy attenuation members3100A,B have a curvilinear configuration that corresponds to the curvature of the inner surface1017of an extent of the side shell portions1024. The left and right energy attenuation members3100A,B also have: (i) first peripheral recesses3424that facilitate engagement of the energy attenuation members3100A,B with the front energy attenuation member3010, (ii) second peripheral recesses3426that facilitate engagement of the energy attenuation members3100A,B with the left and right jaw energy attenuation members3150A,B, and (iii) third peripheral recesses3428that facilitate engagement of the energy attenuation members3100A,B with the rear combination energy attenuation member3200. Like the front energy attenuation member3010, the left and right energy attenuation members3100A,B also include: (i) means for securing or coupling3006, such as hook and loop fasteners sold under VELCRO® or a snap connector, the members3150A,B to the inner shell surface1017, (ii) indicia3012, and (iii) tracking device3014.

The left and right energy attenuation members3100A,B includes two different regions, a fitting region3026and an energy management region3024. Both of these regions3024,3026include strut based lattices; however, these strut based lattices are different from one another. Also, the left and right energy attenuation members3100A,B have the same flexibility in their structural makeup and chemical composition as discussed above in connection withFIGS. 68A-68Cand the front energy attenuation member3010. In other words, the combinations of structural makeups and chemical compositions discussed in connection with front energy attenuation member3010apply with equal force to the left and right energy attenuation members3100A,B. In one exemplary embodiment, the lattice density of the left and right energy attenuation members3100A,B may range between 3 to 7 pounds per cubic foot. It should be understood that the structural makeup and/or the chemical compositions of the left and right energy attenuation members3100A,B may differ from: (i) all other members within the energy attenuation assembly3000, (ii) a percentage of the members within the energy attenuation assembly3000, or (iii) none of the members within the energy attenuation assembly3000. In one embodiment, the left and right energy attenuation members3100A,B may have a denser lattice than the crown energy attenuation member3050.

As shown inFIGS. 67 and 71A-71D, the left and right jaw energy attenuation members3150A,B have a curvilinear configuration that corresponds to the curvature of the inner surface1017of an extent of the ear flap1026portions of the shell1012. The left and right jaw energy attenuation members3150A,B are configured to engage with the left and right energy attenuation members3100A,B. Like the front energy attenuation member3010, the left and right jaw energy attenuation members3150A,B also includes: (i) means for securing or coupling3006, such as hook and loop fasteners sold under VELCRO® or a snap connector, the energy attenuation members3150A,B to the inner shell surface1017, (ii) indicia3012, and (iii) tracking device3014. The left and right jaw energy attenuation members3150A,B includes two different regions, a fitting region3026and an energy management region3024. Both of these regions include strut based lattices; however, these strut based lattices are different from one another. Like the front energy attenuation member3010, the left and right jaw energy attenuation members3150A,B have the same flexibility in their structural makeup and chemical composition as discussed above in connection with the front energy attenuation member3010. In other words, the combinations of structural makeups and chemical compositions discussed in connection with the front energy attenuation member3010apply with equal force to the left and right jaw energy attenuation members3150A,B. In one exemplary embodiment, the lattice density of the left and right jaw energy attenuation members3150A,B may range between 3 to 7 pounds per cubic foot. It should be understood that the structural makeup and/or the chemical compositions of the left/right members may differ from: (i) all other members within the energy attenuation assembly3000, (ii) a percentage of the members within the energy attenuation assembly3000, or (iii) none of the members within the energy attenuation assembly3000. In one embodiment, the left and right jaw energy attenuation members3150A,B may have a less lattice than the front energy attenuation member3010.

As shown inFIGS. 67 and 72A-73, the rear combination energy attenuation member3200has a curvilinear configuration that corresponds to the curvature of the inner surface1017of the extent of the rear portion of the shell1012. The rear combination energy attenuation member3200is configured to engage with the left and right energy attenuation members3100A,B and the crown energy attenuation member3050. Like the front energy attenuation member3010, the rear combination energy attenuation member3200also includes: (i) means for securing or coupling3006, such as hook and loop fasteners sold under VELCRO® or a snap connector, the energy attenuation member3200to the inner shell surface1017, (ii) indicia3012, and (iii) tracking device3014. Like the front energy attenuation member3010, the rear combination energy attenuation member3200has the same flexibility in their structural makeup and chemical composition as discussed above in connection with the front energy attenuation member3010.

This combination member3200could not practically be done using the molding process that is described in U.S. patent application Ser. No. 15/655,490 because the mechanical properties (e.g., absorption of a force) of the members could not be altered enough to optimize how the members, in combination with the shell1012, reacted to an impact force. However, additive manufacturing techniques allow for the creation of a member that has regions with vastly different mechanical properties (e.g., absorption of a force). For example, the combination member3200may be comprised of: (i) consistent composition of one type of polyurethane and a second type of polyurethane, (ii) a first region3210, which has a first lattice cell type and a first density, (iii) a second region3212, which has a first lattice cell type and a second density, (iv) a third region3214, which has a second lattice cell type and a third density, and (v) a3216fourth region, which has a third lattice cell type and a fourth density. Even though the chemical composition of this combination member3200is substantially uniform, the mechanical properties of each region (e.g., first, second, third, and fourth regions) differ due in part to the differing lattice variables that are contained within each region. For example, a compression force will fully compress or bottom out the first region before the third or fourth regions bottom out. Likewise, a compression force will fully compress or bottom out the fourth region before the third region bottoms out.

Another embodiment of the rear combination member3300is disclosed inFIGS. 74A-75C. In particular, this embodiment of the rear combination member3300includes two regions, wherein the first region is3310and the second region is3320. The first region3310is comprised of a fitting region3026. The compressions information associated with this region is shown inFIGS. 74B-74C, which provides the percent the member3010is compressed is shown on the X-axis and the pressure (psi) it takes to compress the member3010to that extent is shown on the Y-Axis. The second region3320is comprised of an energy management region3024. The compressions information associated with this region is shown inFIGS. 75B-74C, which provides the percent the member3010is compressed is shown on the X-axis and the pressure (psi) it takes to compress the member3010to that extent is shown on the Y-Axis. Comparing the first region3310to the second region3320, it can be seen that at an 80% compression level the first region requires approximately 40 psi and the second region requires approximately 200 psi. This is about a five times difference between these regions. Additional information about the compression of these regions is disclosed within the graphs contained herein.

L. Industrial Application

In addition to applying to protective contact sports helmets—namely, football, hockey and lacrosse helmets—the disclosure contained herein may be applied to design and develop helmets for: baseball player, cyclist, polo player, equestrian rider, rock climber, auto racer, motorcycle rider, motocross racer, skier, skater, ice skater, snowboarder, snow skier and other snow or water athletes, skydiver. The method, system, and devices described herein may be applicable to other body parts (e.g., shins, knees, hips, chest, shoulders, elbows, feet and wrists) and corresponding gear or clothing (e.g., shoes, shoulder pads, elbow pads, wrist pads).

As is known in the data processing and communications arts, a general-purpose computer typically comprises a central processor or other processing device, an internal communication bus, various types of memory or storage media (RAM, ROM, EEPROM, cache memory, disk drives etc.) for code and data storage, and one or more network interface cards or ports for communication purposes. The software functionalities involve programming, including executable code as well as associated stored data. The software code is executable by the general-purpose computer. In operation, the code is stored within the general-purpose computer platform. At other times, however, the software may be stored at other locations and/or transported for loading into the appropriate general-purpose computer system.

A server, for example, includes a data communication interface for packet data communication. The server also includes a central processing unit (CPU), in the form of one or more processors, for executing program instructions. The server platform typically includes an internal communication bus, program storage and data storage for various data files to be processed and/or communicated by the server, although the server often receives programming and data via network communications. The hardware elements, operating systems and programming languages of such servers are conventional in nature, and it is presumed that those skilled in the art are adequately familiar therewith. The server functions may be implemented in a distributed fashion on a number of similar platforms, to distribute the processing load.

It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials or embodiments shown and described, as obvious modifications and equivalents will be apparent to one skilled in the art. While the specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention, and the scope of protection is only limited by the scope of the accompanying Claims.