Abstract:
A helmet cover comprising an outer shell and a series of internal supports, wherein the helmet cover further comprises an outer shell comprised of a material designed to fracture at the location of an impact greater than a threshold impact, providing an indicator of the strength and location of the impact, and dispersing the force of the impact around the rigid shell of the helmet. The helmet cover further comprises a marker device adapted to release a marker when an impact greater than a threshold impact is realized on the helmet cover. The helmet cover is preferably a thermoplastic material which is not cellular in nature.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority to U.S. Provisional Patent Application No. 61/506,443, filed on Jul. 11, 2011, entitled “HELMET COVER,” the disclosure of which is hereby incorporated herein by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention generally relates to a helmet cover for a traditional rigid helmet, and more particularly to a helmet cover adapted to indicate when an impact force has been realized on the helmet cover that exceeds a predetermined impact threshold. 
     BACKGROUND OF THE INVENTION 
     Traditional rigid helmets are used to protect the head of an individual from injury or trauma on a jobsite or while participating in various sports. A traditional helmet generally comprises a rigid outer shell having a layer of padding disposed within an interior of the helmet which is adjacent to and in contact with the head of a wearer. The interior padding of the helmet also serves as a cushion to the wearer in the event of an impact force or load realized on the helmet. Traditional rigid helmets used in athletic activities, such as football helmets, have outer shells which are intended to bare the brunt of an impact load during a collision event. The force that traditional rigid helmets are adapted to bare is much greater than a force necessary to cause an injury, such as a concussion, to the individual wearing the helmet. Thus, while the traditional rigid helmet may be intended to bare a great amount of force without fracture or failure, an individual wearing the helmet could receive considerable injury while the rigid outer shell of the traditional helmet would not indicate that such an impact force has been received. For example, some football helmets are designed to have the rigid outer shell maintain its integrity even upon application of forces up to approximately 11,000 pounds per square inch (“psi”). However, an impact load with a force of 11,000 psi realized on a helmet has the potential to cause significant injury to the individual wearing the helmet. Accordingly, it is desirable to provide a helmet cover to cover the outer shell of a traditional rigid helmet, wherein the helmet cover is capable of indicating when an impact force has exceeded a predetermining impact threshold, where the threshold is set at a force level indicating an impact sufficient enough to cause an injury. 
     SUMMARY OF THE PRESENT INVENTION 
     According to one aspect of the present invention, a helmet cover is provided wherein upon impact with a force over a minimum threshold, the helmet cover is fractured. The fracture provides an indication of the strength of the impact force and its location, as well as absorbing and redirecting a portion of the energy transmitted by the impact force. 
     Another aspect of the present invention includes, a helmet cover adapted to cover a traditional rigid shell helmet, wherein the helmet cover is adapted to indicate when an impact force has been realized on the helmet cover that exceeds a predetermined impact threshold. The helmet cover includes an outer shell having a back section, a top section, and side sections. Each section is operably coupled to an adjacent section via hinged connections such that the helmet cover is moveable between an open position and a closed position. A plurality of supports is disposed between and operably coupled to an exterior shell of the rigid helmet and each section of the outer shell. The supports are each adapted to absorb and redirect energy realized on the helmet cover by an impact force. Further, each of the plurality of supports is adapted to collapse under an impact force which exceeds a predetermined impact threshold. The helmet cover further comprises a marker mechanism capable of indicating when the helmet cover has experienced an impact force which exceeds the predetermined impact threshold, wherein the marker is visible and can be seen by either the helmet wearer or others around the individual wearing the helmet. 
     Another aspect of the present invention includes a polymeric helmet cover adapted to cover an exterior shell of a helmet. The helmet cover is adapted to indicate when an impact force has been realized on the helmet cover that exceeds a predetermined impact threshold. The helmet cover includes a plurality of sections wherein each section is operably coupled to adjacent sections such that the helmet cover is moveable between an open position and a closed position. A portion of an outer shell is disposed on an exterior side of each section of the plurality of helmet cover sections. The helmet cover further includes a plurality of supports disposed on an interior side of each section, wherein the supports are disposed adjacent the exterior shell of the helmet covered by the helmet cover. The supports are each adapted to absorb and redirect energy realized on the helmet cover by an impact force during a collision event. The supports are adapted to fracture under an impact force which exceeds a predetermined impact threshold measureable in psi units. A marker mechanism capable of indicating when an impact force has been realized on the helmet cover which exceeds said predetermined impact threshold is also included. 
     Yet another aspect of the present invention includes a polymeric helmet cover adapted to cover a helmet having an exterior shell and indicate when an impact force has been realized on the helmet cover that exceeds a predetermined impact threshold. The helmet cover includes a top section, first and second side sections, and a back section, wherein each section is operably coupled to an adjacent section such that the helmet cover is moveable between an open position and a closed position. An outer shell portion is disposed on an exterior side of the top section, the first and second side sections, and the back section, such that a unitary outer shell is formed when the helmet cover is in the closed position. A plurality of honeycomb supports is disposed on an interior side of the top section, the first and second side sections, and the back section, wherein the supports are disposed adjacent to the exterior shell of the helmet in assembly. The supports are each adapted to absorb and redirect energy realized on said helmet cover by an impact force, and further wherein each of the plurality of supports are adapted to fracture under an impact force which exceeds a predetermined impact threshold. The helmet cover further includes a marker mechanism capable of indicating when an impact force has been realized on the helmet cover which exceeds the predetermined impact threshold. 
     These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the drawings: 
         FIG. 1  is a front elevational view of an interior of one embodiment of the helmet cover in an open position for attachment to a helmet; 
         FIG. 2  is a rear elevational view of the helmet cover shown in  FIG. 1 , showing a partial view of an outer shell; 
         FIG. 2A  is a rear elevational view of the helmet cover shown in  FIG. 1 ; 
         FIG. 3  is a side elevational view of the helmet cover shown in  FIG. 1 , in the closed position showing a full view of the external shell of the helmet cover; 
         FIG. 4  is a bottom plan view of the helmet cover shown in  FIG. 1 , in the closed position; 
         FIG. 5  is a perspective view of a helmet with a helmet cover disposed thereon; and 
         FIG. 6  is a perspective view of a helmet with a helmet cover disposed thereon, wherein the helmet cover has received an impact load causing a stress fracture. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in  FIG. 1 . However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. 
     Referring to  FIG. 1 , the reference number  10  generally indicates a helmet cover according to one embodiment. The helmet cover  10  includes a plurality of sections including a back or rear section  12 , side sections  14 ,  16  and a top section  18 . Each section  12 ,  14 ,  16  and  18  of the helmet cover  10  comprises a portion of an outer shell  20  ( FIGS. 2A and 3 ) disposed on an exterior side of each section ( FIG. 2A ), such that the sections can be moved from an open position ( FIG. 1 ) to a closed or assembled position ( FIG. 3 ) wherein the outer shell portions make up a unitary outer shell  20  to the helmet cover. Thus, the helmet cover  10  can be wrapped or assembled around an exterior shell of a traditional rigid helmet H as shown in  FIG. 5 . The helmet cover sections  12 ,  14 ,  16  can be coupled to the back section  18  in the open position, or can be separate pieces that are only coupled to adjacent sections in the closed position. A series or plurality of supports  22  are disposed on an interior side of each section  12 ,  14 ,  16  and  18  of the helmet cover  10 . The interior side of the helmet cover  10  is shown in  FIG. 1 . In assembly, the supports  22  are disposed adjacent or underneath the outer shell portions of the helmet cover sections  12 ,  14 ,  16  and  18  and are positioned adjacent the exterior shell of helmet H ( FIG. 5 ). As shown in  FIG. 1 , the series of supports  22  are configured in a honeycomb pattern and the supports  22  are adapted to absorb and redirect an impact of a force realized on the helmet cover  10  such that the helmet cover  10  channels the energy of the impact around the helmet H ( FIG. 5 ) as further described below. As shown in  FIGS. 1-4 , the helmet cover sections  12 ,  14 ,  16  and  18  are configured to wrap about the exterior shell of a football helmet H as shown in  FIG. 5 . Thus, the helmet cover sections  12 ,  14 ,  16  and  18  are adapted to provide a reciprocal configuration to the helmet covered by the helmet cover  10 . In  FIG. 5 , a football helmet H is depicted, but it is contemplated that the helmet cover sections  12 ,  14 ,  16  and  18  can be configured to mirror the exterior shell of any helmet to which the helmet cover  10  is applied. 
     Referring to  FIGS. 1-3 , the supports  22  and the outer shell  20  are adapted to collapse or fracture under a predetermined threshold force. The amount of force it takes for the supports  22  to collapse and outer shell  20  to fracture can be refined based on variables such as the material of manufacture, the thickness of the outer shell  20 , the configuration of the supports  22  and the wall thickness of supports  22 . Helmet cover  10  may be optimized in makeup and configuration to obtain a flex-to-fracture ratio in a range of about 5,000 psi to about 7,000 psi as measured by the Notch-Izod testing method standards. An impact force of about 5,000 psi to about 7,000 psi has the potential to injure an individual wearing helmet H with helmet cover  10 , such that an individual receiving such a collision force during a collision event should be observed and the potential injury should be monitored. The ability of the outer shell  20  to fracture serves to indicate both that a potentially medically significant impact has occurred, and also the exact location of the impact force. Preferably, the helmet cover makeup and configuration provides for a helmet cover  10  having a flex-to-fracture ratio of about 6450 psi. Fractures to the outer shell  20  will be indicated at the sight of impact. 
     Materials which may be suitable for use in helmet cover  10  of the present invention include generally rigid polymeric materials having a fracture strength of about 5,000 psi to about 7,000 psi or less, such as certain thermoplastic materials. Appropriate thermoplastic materials may include impact modified polypropylene materials or blends of polycarbonate and polyester materials, such as those in the Xenoy® resin family commercially available at Sabic Innovative Plastics of Pittsfield, Mass. Acrylonitrile butadiene styrene (ABS) thermoplastics can be used to make the helmet cover  10  of the present invention. ABS thermoplastics are available in different grades and can be used for injection molding, extrusion, blow molding, foam molding, and thermoforming. ABS thermoplastics yield plastically at high stresses and the plastic yield can be modified to increase or decrease the impact resistance of the ABS material. For example, increasing the proportions of polybutadiene in relation to the styrene and acrylonitrile will cause for an increase in the impact resistance of the resultant ABS material. Thus, the ABS material for the helmet cover  10  of the present invention can be modified to have an impact resistance or plastic yield in a range of about 5,000 psi to 7,000 psi. The ABS material can be pigmented and are generally considered opaque, translucent, ivory or white in their natural state. The ABS resins can be either pigmented or coated to increase weather resistance or to produce a product having a plastic shiny or acrylic appearance. Further, the temperature at which an ABS plastic is molded can affect the impact resistance and strength of the ABS material. For example, molding at a lower temperature will increase the impact resistance and strength of the material while molding at a higher temperature will make the ABS product less impact resistant. Under high stresses, ABS plastics can stress-whiten at an area of impact which provides for a marker mechanism in the helmet cover  10  of the present invention as further described below. The polymeric material makeup of helmet cover  10  preferably has a specific gravity in the range of 1.0-1.5 grams/cu cm, in order to maintain a low profile and to reduce the weight of the helmet cover  10 , such that the overall weight of helmet H to which the helmet cover  10  is attached is not greatly altered. 
     Having a polymeric material with a fracture strength in a range of about 5,000 psi to about 7,000 psi, the back section  12 , side sections  14 ,  16  and top section  18  of the helmet cover  10  are generally rigid pieces with some ability to flex under lower impact loads, such as loads under 5000 psi. Thus, the supports  22  and outer shell  20  of sections  12 ,  14 ,  16  and  18  of the helmet cover  10  are designed to resist fracture when lower impact loads occur. Thus, the helmet cover  10  of the present invention is adapted to withstand impact forces of normal work or sports activities without needing replacement. While the helmet cover  10  described herein and shown in the accompanying figures depicts a helmet cover for use with a traditional football helmet, it is contemplated that the helmet cover of the present invention can be configured for use with any helmet used for any type of sports activity such as cycling, hockey, lacrosse, skiing, hiking, climbing, snowboarding and other such activities where a helmet is generally used. Further, the helmet cover  10  of the present invention can also be used with work related activities such as in the construction or road repair industries for example. Also, it is contemplated that the helmet cover  10  of the present invention will also have military applications to indicate when a wearer has received a potentially dangerous impact in the field. 
     The side sections  14 ,  16  of the helmet cover  10  are coupled to the back section  12  as shown in  FIG. 1  via hinges  24 ,  26 . Top section  18  is also attached to the back section  12  via a hinge  28 . As shown in  FIGS. 1 and 2 , the hinges  24 ,  26  and  28  are preferably integrally formed with the helmet cover sections such that the entire helmet cover  10  can be formed from one piece to provide a unitary helmet cover  10  sectionally divided into sections  12 ,  14 ,  16  and  18 . Further, it is contemplated that the hinges  24 ,  26  and  28  can be integrally formed living hinges which can be in the form of a flexible resilient polymeric material having a thinned wall section which allows for flexing at the hinged location, or can be a specific configuration of polymeric material which allows for resilient flexing such as a zigzag configuration. 
     Helmet cover  10  is shown in the open position in  FIGS. 1-2 , and in the assembled or closed position in  FIGS. 3-4 . When helmet cover  10  is in the closed position, each of the rigid sections  12 ,  14 ,  16  and  18  fits over the rigid exterior shell of helmet H. When in the closed position, helmet cover  10  comprises an outer shell  20  having a shape generally similar to that of the traditional helmet H, with a series of supports  22  supporting and reinforcing the outer shell  20 , located between an exterior shell of helmet H and outer shell  20  of the helmet cover  10 . 
     Helmet cover sections  12 ,  14 ,  16  and  18  have complimentary shaped intersecting edges  30 ,  32 ,  34  and  36  such that the helmet cover sections  12 ,  14 ,  16  and  18  can be tightly and securely closed to form an essentially unitary outer shell  20  ( FIG. 3 ). The intersecting edges  30 ,  32 ,  34  and  36  can be complimentary in that they comprise tongue and groove configurations where adjacent edges intersect. Any other form of grooved overlay between adjacent sections is also contemplated for use with the intersecting edges  30 ,  32 ,  34  and  36  to guide the closing of the helmet cover  10  and assure proper assembly. A snap-fit assembly of intersecting edges is also contemplated to securely hold the helmet cover sections in place on the helmet H. Specifically, as shown in  FIGS. 1 and 2 , complimentary edges  30 ,  36  are disposed along the back section  12  and the top section  18  respectively. Edges  30 ,  36  are complimentary to edges  32 , and  34  disposed on an outer perimeter of side sections  14 ,  16 . The complimentary edges  30 ,  32 ,  34  and  36  and supports  22  on the interior portion of each section  12 ,  14 ,  16  and  18  are configured to appropriately interact to transfer energy between supports  22  of adjacent sections  12 ,  14 ,  16  and  18  when an impact load is realized on the helmet cover  10  in the closed position. Thus, as an impact load is realized on the helmet cover  10  during a collision event, the section of the helmet cover  10  absorbing the brunt of the impact force is aided by the ability of that section to redirect the impact force into adjacent sections  12 ,  14 ,  16  and  18  and the supports  22  associated with those sections. The redirection of the impact force is caused by the supports  22  and the lateral edges disposed between helmet sections that are connected in such a manner that energy can be transferred from one section to the next adjacent section. Thus, if an impact force where to occur where side section  16  received the brunt of the impact force, the outer shell  20  would stress whiten or fracture (based on the amount of force received), and the energy of that impact force would transfer and spread physically to adjacent helmet sections  12 ,  18  through the intersecting edges  30 ,  34  and  36  which are tightly interconnected without gaps to allow the impact force energy to effectively transfer and spread. 
     Sections  12 ,  14 ,  16  and  18  of the helmet cover  10  may also be provided with specific features designed to interact with the desired helmet H. Such features can include openings or apertures  38 , such as those disposed on top section  18  and side sections  14 ,  16  as shown in  FIG. 1 , whereby the apertures  38  can align with and accommodate vents disposed on exterior shell of helmet H. Further, the helmet cover  10  can comprise apertures  40  adapted to accommodate the fastening of a face mask  50  ( FIG. 5 ) or other add-ons of a particular helmet H. 
     To close helmet cover  10  from an open position ( FIG. 1 ) to an assembled position over helmet H ( FIG. 5 ), back section  12  is aligned with the center, rear portion of helmet H as side sections  14 ,  16  are folded inward until they have made contact with the outer rigid shell of helmet H. Next, top section  18  is folded downward, such that its lateral edges  36  interact with and engage edges  32 ,  34  of right and left side sections  14 ,  16 . Thus, as shown in  FIG. 4 , the helmet cover  10  is in a closed position with side sections  14 ,  16  being folded inward such that lateral edges  32 ,  34  of the side sections  14 ,  16  are shown within the interior of the helmet cover  10  as shown in  FIG. 4 . Thus, in the closed position, as shown in  FIG. 4 , the lateral edges  36  of the top section  18  are disposed over the lateral edges  32 ,  34  of the side sections  14 ,  16 . 
     Helmet cover  10  can be secured to helmet H using screws or other like fasteners  42  received through reinforced holes  44  disposed in top section  18 . Additionally, fasteners such as snaps, hook and loop closures, adhesives or other fastener means can also be used to secure helmet cover  10  to the rigid outer shell of helmet H. Further, it is contemplated that reinforcing attachment apertures, such as reinforced holes  44 , can be used in other locations on various sections of the helmet cover  10  to secure the helmet cover  10  to the rigid outer shell of helmet H. 
     The helmet cover  10  is preferably removably securable to helmet H, so that the helmet cover  10  can be removed from helmet H if the helmet cover  10  is damaged. As the helmet cover  10  is designed to fracture with an impact force less than that necessary to fracture helmet H over which it is placed, and because the helmet cover  10  absorbs and redirects the force of the impact, helmet H will receive less impact force than helmet cover  10  and may be undamaged by the force applied to helmet cover  10 . Therefore, a damaged helmet cover  10  can be removed from helmet H, and a new helmet cover  10  secured to helmet H in its place. 
     The hinged connection of sections  12 ,  14 ,  16  and  18  of helmet cover  10  allows the helmet cover  10  to be easily installed on helmets H and also permit formation of helmet cover  10 , including outer shell  20  and supports  22 , in a single molding process using a mold which does not have any sliding or moving parts. This is because helmet cover  10  opens ( FIG. 1 ), so that there are no opposing sides or interior sides, and a die which is moved in only one axis is able to stamp or injection mold the part. 
     As noted above, the helmet cover  10  has an outer shell  20  which is adapted to fracture when an impact load is realized on the outer shell  20  that is above a predetermined threshold force. The helmet cover  10  can be configured such that the threshold force is a force within a range from about 5,000 psi to 7,000 psi, or more preferably 6450 psi. As noted above, the impact force required to fracture the outer shell and collapse the supports  22  of the helmet cover  10  can be tailored by the configuration of the supports  22 , the materials used to make the supports  22 , the materials used to make the outer shell  20  and other such factors which would cause the threshold impact force to increase or decrease in assembly. Having helmet cover  10  with indicating fractures disposed on the outer shell  20  after an impact force has been realized that exceeds the impact force threshold for the helmet cover  10 , allows for those around the individual wearing the helmet H to identify that a potentially dangerous impact has occurred. Thus, a fellow team member, coach or observer, can identify that a potentially dangerous impact has occurred such that the individual wearing the helmet H can be monitored for signs of injury or concussion. 
     The helmet cover  10  of the present invention further includes a marker mechanism which works in conjunction with the fracturing capabilities of the outer shell  20  and supports  22  to indicate that a serious impact has been realized on the helmet cover  10 , and where that impact has occurred. 
     As shown in  FIG. 6 , the helmet cover  10  is shown disposed on an exterior shell of helmet H wherein a stress fracture  60  is shown with an area  62  that has been stress-whitened by the impact received which caused the fracture  60 . The stress fracture  60  has also caused polymer particles  64  to be released from the polymeric makeup of the helmet cover  10  such that these polymer particles, or ABS thermoplastic particles, are now deposited around the stress fracture  60  on the outer shell  20  of the helmet cover  10 , thereby marking the area of impact. Such particles are also released as the supports  22  are fractured or collapse under an impact load wherein the particles would then be deposited on the exterior shell of the helmet H. In this way, the present invention indicates on the helmet cover where an impact has occurred that exceeds a predetermined impact threshold, such that the wearer of the helmet H with the helmet cover  10  can be appropriately cared for at the specific location of impact. Thus, the marker mechanism includes one or more fractures  60  to the unitary outer shell occurring during a collision event, wherein an impact force is realized on the helmet cover that exceeds the predetermined impact threshold. The marker mechanism further includes a deposit of polymer particles  64  released during the fracturing of the unitary outer shell  20  of the helmet cover  10 . 
     As noted above, the polymeric material making up the helmet cover  10  can be a pigmented ABS thermoplastic such that when a stress fracture occurs, the particles  64  released from the stress fracture can be a contrasting color as compared to the exterior shell of the helmet H. In this way, the particles  64  released due to a fracture of the outer shell  20 , the supports  22 , or any other part of the helmet cover  10 , can be easily identified against the exterior shell of the helmet H. Further, the helmet cover  10  can be impregnated with a dark color, such as black, to help indicate when a high impact has been received causing the ABS thermoplastic to stress-whiten at the point of impact. The stress-whitening, such as the stress-whitening area  62  shown in  FIG. 6 , can be more pronounced against a dark pigmented helmet cover. Thus, the helmet cover of the present invention can mark an area of impact by a stress fracture  60 , stress-whiten areas  62 , or polymer particles  64  being released from the polymeric material of the helmet cover  10 . 
     The helmet cover  10  of the present invention serves to disperse forces of an impact load realized on the helmet cover  10  such that when the impact load realized on the helmet cover  10  exceeds a threshold impact load, the helmet cover  10  can indicate the specific location on the helmet cover  10  where the impact load was realized. The impact load indicators can be in the form of physical fractures  60  ( FIG. 6 ) disposed on the outer shell  20 , or particles  64  released due to the fracture, or a mark on the helmet cover caused by stress-whitening  64 . These load indicators or marker mechanisms allow the wearer of the helmet, and others around the wearer, to know when a potentially dangerous impact force has occurred during a collision event, whereas the helmet, covered with the helmet cover, alone would not such a potentially dangerous impact occurrence. Being susceptible to breakage at about 11,000 psi, the helmet alone does not indicate when potentially dangerous impacts have occurred. 
     It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.