Football helmet with recessed face guard mounting areas

A protective football helmet is provided having a face guard mounting system with at least one pair of opposed recessed mounting regions that ensure a low-profile mounting arrangement for a face guard to the helmet. The recessed mounting regions are formed in both the inner and outer surfaces of the helmet shell along a frontal opening in the shell. As a result of the streamlined frontal appearance provided by the face guard mounting system, the width of the face guard closely corresponds to the width of the helmet at the recessed mounting regions.

TECHNICAL FIELD

The invention relates to a protective football helmet that features a low-profile mounting configuration for a face guard that protects the player's facial area. The helmet includes an outer shell with recessed frontal mounting areas that ensure a low-profile connection of the face guard to the helmet.

BACKGROUND OF THE INVENTION

Protective helmets for contact sports, such as those used in football, hockey and lacrosse, typically include a rigid outer shell, an internal pad assembly coupled to an interior surface of the shell, a face guard or face mask, and a chin protector or strap that removably secures the helmet on the wearer's head. The face guard covers a front opening of the helmet shell and protects the wearer's facial area. Conventional face guards are formed from a plurality of intersecting elongated bars that define apertures through which the wearer looks through while participating in the contact sport. The face guard is secured to the helmet by connectors and brackets that fasten to the outer surface of the helmet shell. In this manner, the face guard resides external to and outside of the helmet shell.

In the last decade, the overall size of conventional protective helmets, including the helmet shell, has increased in an effort to improve the helmet's performance and impact performance. As the helmet size increases, the frontal profile of these helmets has also increased. The frontal profile is further increased when the face guard is secured to the helmet shell. The resulting frontal profile of the helmet and the face guard connected thereto can be visually dominant and unappealing to wearers of the helmet, as well as potential wearers of the helmet.

Features and advantages of the invention will be apparent to those skilled in the art upon review of the following detailed description and accompanying drawings.

SUMMARY OF THE INVENTION

The invention provides a football helmet having a low-profile face guard mounting configuration that provides a streamlined frontal appearance. The helmet includes a one-piece shell having a crown portion defining an upper region of the shell, a front portion extending generally forwardly and downwardly from the crown portion, left and right side portions extending generally downwardly and laterally from the crown portion. The front portion and the left and ride side portions collectively define a frontal opening in the shell, wherein the front opening includes opposed peripheral frontal edges. A lower recessed face guard attachment region extends along a lower extent of the opposed peripheral frontal edges and an upper recessed face guard attachment region extends along an upper extent of the opposed peripheral frontal edges. A face guard has opposed lower peripheral portions and opposed upper peripheral portions. To provide the low-profile face guard mounting configuration, the lower peripheral portions are secured to the lower recessed attachment regions by lower connector brackets and the upper peripheral portions are secured to the upper recessed attachment regions by upper connector brackets.

DETAILED DESCRIPTION

FIGS. 1-15illustrate a football helmet10with a durable, one-piece molded shell12that includes a face guard mounting system50featuring recessed mounting areas54,56that ensure a low-profile connection of the face guard200to the helmet10. This low-profile connection arrangement results in a streamlined, low-profile frontal appearance of the helmet10. In particular,FIGS. 1, 2, 3A, 6 and 11-15show the face guard200connected to the helmet10in the low-profile configuration. As a result of streamlined frontal appearance provided by the face guard mounting system50, the width of the face guard200closely corresponds to the width of the helmet10at the recessed mounting areas54,56. It is understood by those of skill in the art of designing protective sports helmets that different regions of a football helmet experience impacts of different types, magnitudes and durations during the course of playing the particular sport. It is also understood that the types, magnitudes and durations of impact forces upon a helmet are different in football, hockey and lacrosse because these sports differ in many significant ways, e.g., the underlying nature of the play, the number and type of players, the equipment worn by the players, and the playing surface. It is further understood that while playing football, a player may experience multiple impacts to the same or different regions of the helmet during a single play or a series of plays.

FIG. 1shows the helmet10being worn by a wearer or player P. In addition to the face guard mounting system50, the helmet10includes the shell12, the facemask or face guard200attached at upper and lower frontal regions of the shell12by removable upper and lower connectors211,213. The face guard200comprises an arrangement of elongated and intersecting bar members212and is designed to span a frontal opening14in the shell12to protect the facial area and chin of the player P. The one-piece, molded (either injection or thermoformed) shell12is formed from impact resistant plastic or polymer materials, such as polycarbonate, acrylonitrile butadiene styrene (ABS), or nylon. The helmet10also includes a chin strap assembly300and an internal pad assembly400(seeFIGS. 1, 2 and 14) that is detailed below.

As shown in the Figures, the shell12includes a curvilinear outer surface16featuring complex contours and facets. The shell12also includes a crown portion18defining a top region of the helmet10, a front portion20extending generally forwardly and downwardly from the crown portion18, left and right side portions24extending generally downwardly and laterally from the crown portion18, and a rear portion22extending generally rearwardly and downwardly from the crown portion18. The left and right side portions24each include an ear flap26positioned generally to overlie and protect the ear region of the player P when the helmet10is worn. Each ear flap26may be provided with an ear hole30to improve hearing for the wearer. The shell12is symmetric along a vertical plane dividing the shell12into left and right halves. When the helmet10is worn by the player P (seeFIG. 1), this vertical plane is aligned with the midsagittal plane that divides the player P (including his or her head) into symmetric right and left halves. Therefore, features shown in Figures as appearing in one half of the shell12are also present in the other half of the shell12. The helmet also has an engineered impact attenuation system that includes an impact attenuation member42which adjusts how the portion of the helmet10including the member42responds to impact forces compared to adjacent portions of the helmet10lacking the member42. The impact attenuation member42is formed by altering at least one portion of the shell12wherein that alteration changes the configuration of the shell12and its local response to impact forces applied substantially normal to the front shell portion20. For example, in the illustrated configuration, the impact attenuation member42includes a cantilevered segment or flap44formed in the front shell portion20. Compared to the adjacent portions of the shell12that lack the cantilevered segment44, the cantilevered segment44improves the attenuation of energy associated with impacts to at least the front shell portion20.

As shown inFIGS. 3B, 7 and 9, the frontal opening14in the helmet10is defined by a frontal edge13of the shell12wherein the frontal edge13includes left and right peripheral frontal edges13aand a central frontal edge13bthat extends horizontally between the opposed peripheral frontal edges13awhich are substantially vertically oriented. The shell12also includes a pair of jaw flaps34, with each jaw flap34extending generally forwardly from a respective one of the ear flaps26for protection of the mandible area of the player P. The face guard mounting system50(seeFIG. 1) includes at least one recessed mounting region that extends vertically along the peripheral frontal edges13aof the helmet shell12. In the illustrated configuration, each jaw flap34includes a first or lower recessed face guard attachment region54adjacent a lower extent13a2of the peripheral frontal edge13a. A second or upper recessed face guard attachment region56is provided adjacent an upper extent13a1of the peripheral frontal edge13a. The lower and upper recessed face guard attachment regions54,56have a generally trapezoidal configuration. Each attachment region54,56includes an aperture33that receives an elongated fastener215extending through the face guard connector211,213to removably secure the face guard200to the shell12. As explained below, the lower face guard attachment region54is recessed inward compared to the adjacent outer surface34aof the jaw flap34, and the upper face guard attachment region56is recessed inward compared to the adjacent outer surface26aof the ear flap26.

As shown inFIGS. 3B, 7 and 9, there is a sloped or angled transition wall58extending inward (towards the head of player P when the helmet10is worn) from the ear flap outer surface26aand the jaw flap outer surface34ato the recessed attachment regions54,56. Preferably, the transition wall58is oriented at an angle θ greater than 90 degrees and less than 150 degrees (seeFIG. 7). Due to this arrangement, the outer surface54aof the lower recessed region54is recessed inward from the jaw flap outer surface34and the outer surface56aof the upper recessed region56is recessed inward from the ear flap outer surface26a. The transition wall58extends rearward at a slight incline from the central frontal edge13band then downward and in close proximity to the peripheral edge13a, then away from a frontal jaw flap edge37a, and then downward to a lower jaw flap edge37b. Accordingly, the transition wall58has multiple segments including a first lateral segment58a, a first downward segment58b, a second downward segment58c, a third downward segment58dand a fourth downward segment58ethat leads to the lower jaw flap edge37b. Referring toFIG. 7, the transition wall58extending from the ear flap26to the jaw flap34and the recessed face guard attachment regions54,56collectively form a corrugation in the helmet shell12, and thus do not involve either the removal of material from the shell12or a reduction in the wall thickness TSof the shell12. Thus the shell's wall thickness TSremains substantially constant across the majority of these regions of the shell12.

FIG. 8shows the features of the inner shell surface17of the shell12including the ear opening30, the recessed face guard attachment regions54,56and the transition wall58. Because the lower and upper recessed face guard attachment regions54,56are recessed from the outer surface shell surface16, these features have a raised or embossed appearance compared to the inner shell surface17. Thus, these features are present and visually apparent in both the outer shell surface16and the inner shell surface17. Furthermore, the inner surface54bof the lower attachment region54and the inner surface56bof the upper attachment region56are recessed inward of the inner shell surface17. The upper recessed attachment region56also includes a substantially circular boss56cformed on the inner shell surface17around the aperture33. Similarly, the lower recessed attachment region54includes a generally trapezoidal boss54cformed on the inner shell surface17around the aperture33.

Referring toFIG. 7, the transition wall58is stepped inward to form the corrugation in the shell12discussed above. At the apex58fbetween the second and third downward segments58c,d, the transition wall58has a height HWof at least 0.125 inch, preferably at least 0.15 inch and most preferably between 0.15 inch and less than 0.275 inch. At the apex58f, the transition wall58has a thickness TWalong its sloped surface of at least 0.25 inch, preferably at least 0.275 inch and most preferably at least 0.3 inch and less than 0.5 inch. At a midpoint of the fourth downward segment58ethat leads to the lower jaw flap edge37b, the transition wall58has a reduced slope and thus a thickness TWalong its sloped surface of at least 0.3 inch, preferably at least 0.4 inch and most preferably at least 0.5 inch and less than 0.75 inch. The shell12has a nominal wall thickness TSof 0.125 inch±0.005 inch. These dimensions of the transition wall58and shell12ensure that the structural rigidity and flexural modulus of the helmet10are sufficiently high to enable the helmet10to withstand multiple impacts and impact forces, including those resulting from frontal impacts and slightly off-center frontal impacts.

FIGS. 9 and 10provide a side-by-side view of the shell12of the inventive helmet10and the shell512of a prior art helmet500that lacks the lower and upper recessed face guard attachment region54,56and a number of other structural features of the helmet10. The shell12and shell512have substantially the same outer dimensions, for example outer width and overall height. Although not shown with the helmet500ofFIG. 10, some prior art football helmets include additional material added to the shell in the area surrounding the frontal opening and along the peripheral frontal edges and a central frontal edge that define the front opening.FIGS. 11A and 12Aprovide a side-by-side view of the inventive helmet10, including the face guard200secured to the helmet10by the connectors211,213, and the prior art helmet500, including face guard700secured to helmet500by the connectors511,513. For reference purposes, the prior art helmet500closely corresponds to the Riddell 360® football helmet, which was designed and currently marketed by Riddell, Inc., the Assignee of the present Application. The helmet10and the helmet500depicted inFIGS. 11 and 12are adult size large models, which correspond to a hat size of 7-7.5 and a head circumference of 22-23.5 inches. These two Figures show the low-profile mounting arrangement of the face guard200to the helmet10as provided by the lower and upper recessed face guard attachment region54,56. The distance between the upper face guard connectors211,511represents the face guard width WFG. Due to the lower and upper recessed face guard attachment region54,56and the resulting low-profile mounting of the face guard200, the face guard width WFGof the helmet10is considerably less than the face guard width WFGof the prior art helmet500, which lacks the low-profile mounting of the face guard700. In addition, the distance D1between the center of mass and the upper face guard connector211for the helmet10is less than the distance D1between the center of mass and the upper face guard connector511for the prior art helmet500. Similarly, the distance D2between the center of mass and the lower face guard connector213for the helmet10is less than the distance D2between the center of mass and the lower face guard connector513for the prior art helmet500.

FIG. 11Bis an enlarged view of the football helmet10showing an offset distance O between the outer shell surface16and the outermost surface255bof the terminal end255of the upper connector right bracket211.FIG. 12Bis an enlarged view of the football helmet510showing an offset distance O between the outer shell surface516and the outermost surface555bof the terminal end555of the upper connector right bracket511. As shown inFIGS. 11B and 12Band due to the low-profile connection of the face guard200to the helmet10, the offset O for the helmet10is considerably less than the offset O for the prior art helmet510. In the embodiment of the Figures, the offset O of the helmet10is less than 0.5 inch, preferably less than 0.45 inch and most preferably is 0.4 inch. Furthermore, the upper peripheral face guard portion220is closer to the outer shell surface16of the helmet10(seeFIG. 11B) compared to the distance between the upper peripheral face guard portion720and the outer shell surface516of the helmet510(seeFIG. 12B). Referring toFIG. 13, there is an arc length AL extending along the uppermost bar230of the face guard200of the helmet10. The uppermost bar230extends along the front shell portion20but does not contact the lower front shell portion20a. Because of the lower and upper recessed face guard attachment regions54,56and the resulting low-profile connection of the face guard200to the helmet, the arc length AL is less than the AL in the prior art helmet500(not shown).

Referring toFIG. 2, when the face guard200is secured to the shell12, a lower peripheral portion225of the face guard200resides within the periphery of the lower recessed attachment region54, which is bounded by the transition wall58. Referring toFIGS. 6 and 15, when the face guard200is secured to the shell12, an upper peripheral portion220of the face guard200having a U-shaped configuration resides within the periphery of the upper recessed attachment region56, which is also bounded by the transition wall58. The elongated fastener215is a multiple component, quick-release fastener that is described in co-pending U.S. patent application Ser. No. 12/082,920 and extends through the connector brackets211,213. A grommet240is positioned within the aperture33in the upper attachment region56wherein the fastener215and a retainer250extend through the grommet240. The connector bracket211,213has a clam shell configuration and includes an inner segment251and an outer segment253that converge to form a bulbous terminal end255. The terminal end255defines a receiver256that envelops or receives an extent of the peripheral portion220of the face guard200. Adjacent the peripheral portion220, the inner and outer segments251,253include a recess257,259leading to the aperture258that receives the fastener215in the secured position SP ofFIGS. 6 and 15. The inner and outer segments251,253meet at a seam S that extends longitudinally from a leading end254to the receiver256. In the secured position SP, an inner portion255aof the terminal end255and the inner bracket segment251reside inward of the outer shell surface16, including the outer ear flap surface26a, while an outer portion255bof the terminal end255resides outward of the outer shell surface16. Also in the secured position SP ofFIGS. 6 and 15, an inner surface220a1provided by an inner portion220aof the peripheral face guard portion220both reside inward of the outer shell surface16, including the outer ear flap surface26a, while an outer surface220b1provided by outer portion220bresides radially outward of the outer shell surface16. These positional relationships are primarily due to the upper recessed attachment region56which, along with the lower recessed attachment region54, provide the low-profile connection of the face guard200to the helmet shell12.

Referring toFIG. 14, the face guard200has a lower bar260that has opposed substantially linear peripheral segments262, substantially linear inward transition segments265and a curvilinear intermediate segment270. The peripheral and transition segments262,265combine to follow along the radius of curvature (shown in dotted lines) defined by the lower edge37bof the jaw flap54. The configuration of the lower bar260, including its segments262,265and270, and the jaw flap54further ensure the low-profile mounting configuration of the face guard200to the shell12. As shown in the Figures, the helmet10includes four distinct recessed regions—a pair of first or upper recessed attachment regions56and a pair of second or lower recessed attachment regions54—and four distinct face guard connectors—a pair of first or upper connectors211and a pair of second or lower connectors213—that collectively provide four connection points for the face guard200to the shell12. This configuration renders unnecessary the need for a connection point along the lower front shell portion20afor the upper bar of the face guard200. In another embodiment, the helmet10is configured with either the upper recessed attachment regions56and connectors211, or the lower recessed attachment regions54and connectors213along with a connection point on the front shell portion20along the central frontal edge13b. This frontal connection point can have a recessed configuration consistent with the upper and lower recessed attachment regions54,56. This alternate configuration provides four face guard connection points, wherein at least two of the connection points feature a recessed attachment region.

As shown inFIG. 2, chin strap securement member310is positioned rearward of the upper face guard attachment region56and is configured to receive an upper strap member312of the chin strap assembly300. A multi-adjustable chin strap securement member320, which is positioned rearward of the lower face guard attachment region54and along a lower side shell edge13c, is configured to receive a lower strap member314of the chin strap assembly300. The multi-adjustable chin strap securement member320is received by a receptacle325(seeFIG. 3B) formed in a lower portion of the shell12. In the use position shown inFIGS. 1 and 3, the upper strap member312extends between the upper peripheral portion220of the face guard200and the upper attachment region56. More specifically, the upper strap member312extends through a gap or clearance formed between the outer surface of the upper attachment region56and the inner surface of the upper peripheral face guard portion220. The upper strap member312can engage the second downward segment58cof the transition wall58.

The helmet10also includes a raised central band62that extends from the front shell portion20across the crown portion18to the rear shell portion22. The band62is defined by a pair of substantially symmetric raised sidewalls or ridges66a,66bthat extend upwardly at an angle from the outer shell surface16. When viewed from the side, the sidewalls66a,66bdefine a curvilinear path, preferably continuous, as they extend across the crown portion18to the rear shell portion22. As shown inFIG. 13, a front portion64of the band62is coincident with the impact attenuation member42and is positioned a distance above the central frontal edge13b. Referring toFIGS. 4 and 5, the band62has a width that increases as the band62extends from the front shell portion20across the crown portion18to the rear shell portion22. As shown inFIGS. 3, 4 and 7, a rear portion68of the band62is coincident with and merges with a rear raised band70that extends transversely between the left and right side portions24of the shell12. Similar to the sidewalls66a,66b, the rear band sidewalls72,74are sloped meaning they extend outwardly and upwardly at angle from the outer shell surface16. Referring toFIG. 4, a lower channel80extends transversely below the raised rear band70and above a lower rear shell edge81.

As shown in the Figures, the helmet10further includes numerous vent openings that are configured to facilitate air circulation within the helmet10when it is worn by the player P. A first pair of vent openings84are formed in the crown portion18, wherein the left vent opening84ais substantially adjacent the left sidewall66aand the right vent opening84bis substantially adjacent the right sidewall66b. A second pair of vent openings86are formed in the rear shell portion22, wherein the left vent opening86ais substantially adjacent the left sidewall66aand left band sidewall72, and the right vent opening86bis substantially adjacent the right sidewall66band right band sidewall74. The left first and second vent openings84a,86aare substantially aligned along the left sidewall66a, and the right first and second vent openings84a,86aare substantially aligned along the right sidewall66b. A third pair of vent openings88are formed in the rear shell portion22below the rear raised band70, wherein the left vent opening88ais positioned adjacent a left ridge87aand the right vent opening88bis positioned adjacent a right ridge87b. A fourth pair of vent openings90are formed in the front shell portion20, wherein the left vent opening90ais positioned adjacent a left frontal ridge92aand the right vent opening90bis positioned adjacent a right frontal ridge92b. The frontal ridges92a,bare located between the front shell portion20and the side portion24and thus generally overlie the temple region of the player P when the helmet10is worn. The first, second, third and fourth vent openings84a,b,86a,b,88a,band90a,bare cooperatively positioned with voids in the internal padding assembly400to facilitate the flow of air through the helmet10.

As shown inFIG. 14, the helmet10includes an internal padding assembly400with a front pad410that structurally and functionally interacts with the impact attenuation member42. As such, the engineered impact attenuation system comprises both the cantilevered segment44and the front pad410. The internal padding assembly400also comprises a crown pad assembly412, left and right ear flap pad assemblies414a,b, left and right jaw flap pad assemblies416a,b, and rear pad assembly418. The internal padding assembly400also includes a relatively thin, padded overliner420that is positioned against the player's P head when the helmet10is worn. It is understood that the overliner420, the crown pad assembly412, the left and right ear flap pad assemblies414a,b, the left and right jaw flap pad assemblies416a,b, and the rear pad assembly418can include a number of distinct pad members formed from one or more energy absorbing materials.

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; for example, the entire cantilever strap could be provided with a shock absorbing pad disposed upon its lower surface. Accordingly, the invention is therefore to be limited only by the scope of the appended claims. 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.