Abstract:
A protective component for use within a protective helmet such as a football helmet that includes one or more spider web-like structures formed from a fine but strong polymeric fiber, preferably artificial spider web silk. The one or more spider web layers are spaced apart one from another as well as from any conventional padding foam lining the hard shell of a helmet. The web layer or layers is/are independently attached to the helmet shell, generally by their edges. The innermost web layer surrounds and conforms to a wearer&#39;s head. The spider web elements provide excellent protection to the head of a wearer of the protective helmet. The use of the inventive web layers allows the production of fewer helmet sizes while still resulting in a perfect conformal fit to a wide range of head sizes and/or shapes within a particular helmet size.

Description:
RELATED APPLICATIONS 
     This application claims priority under 37 C.F.R. §1.119(e) to U.S. Provisional Patent Application No. 61/519,067 for SPORT&#39;S HELMET PADDING COVERED WITH SPIDER WEB TECHNOLOGY, filed May 16, 2011 and which is incorporated herein in its entirety by reference. 
    
    
     FIELD OF THE INVENTION 
     The invention pertains to sports helmets and, more particularly, to one or more protective layers incorporating a spider web-like structure for inclusion within a football helmet or the like. 
     BACKGROUND OF THE INVENTION 
     Currently, the news abounds with yet another story of head or neck injuries incurred by a participant in a sport such as football or while engaging in other recreational activities. Similar injuries are common among operators of equipment such as motor cycles, all terrain vehicles (ATV&#39;s), snow machines or snow mobiles, or other similar equipment. Still other styles of protective headgear are worn by on the job by workers in certain jobs. 
     As used herein, the term protective headgear will be applied to all protective helmets suitable for use in work, athletic endeavors or while operating motorcycles or other such devices. While a football helmet is used herein for purposes of disclosure, it will be recognized that many other forms of protective headgear may incorporate the novel spider web structures of the present invention. Therefore, for the sake of brevity, the term football helmet is used hereinafter to represent all such protective headgear. 
     There are many types of protective headgear known in the prior art. For such headgear to be effective in protecting a wearer thereof, it must fit properly. For wide acceptance by persons in need of head/neck protection, such headgear must be comfortable when worn. Such headgear typically uses padding applied to a hard outer shell to cushion the wearer&#39;s head from impacts 
     Human heads come in a wide variety of sizes and shapes. Manufacturers of such headgear must, therefore, provide headgear in a wide range of sizes and styles to properly protect this variety of head sizes and shapes. 
     A typical protective helmet consists of a hard, molded, polymeric outside shell with a molded foam padded insert sized and shaped to conform to a specific head size and shape. This construction creates manufacturing inefficiencies because manufacturers have heretofore needed to provide tooling (e.g., molds) to produce molded padding inserts to fit these aforementioned diverse head styles and shapes. Even with a range of sizes available in each style helmet produced, a perfect fit was not obtained by many users of the helmets of the prior art. 
     During the early twenty-first century, deaths of professional football players began to be linked to multiple concussions received during those players&#39; playing careers. In response to allegations being made that the current generation of football helmets were not providing the protection advertised by their manufacturers, United States Senator Thomas Udall urged the Federal Trade Commission (FTC) in the United States to look at the problem of concussions received by football players. Specifically, Senator Udall asked the FTC to investigate “misleading safety claims and deceptive practices” of football helmet manufactures. [New York Times, Jan. 4, 2011, Page B10] In early 2011 the FTC announced that it would independently test the safety claims made by manufacturers of football helmets. 
     As awareness of the possible inadequacy of football helmets to properly protect players of the game spread, many questions began to be raised as to how protective helmets could be improved. The novel spider web-based technology of the present invention offers an answer to how to better protect the heads and necks of helmet wearers (e.g., football players) exposed to impacts to the head and neck region of their bodies. 
     DISCUSSION OF THE RELATED ART 
     Attempts at improving helmets such as football helmets may be found in the prior art. For example, U.S. Pat. No. 4,982,451 for HEAD COVERING DEVICE issued Jan. 8, 1991 to Richard T. Graham teaches a head covering device having a resilient adjustable liner with a deformable fabric crown removably attached thereto. 
     U.S. Pat. No. 6,880,176 for HEADGEAR issued Apr. 19, 2005 to Richard M. Timms et al. provides improved headgear having an outer shell and an inner liner providing a head receiving cavity. A headband has a forward portion and lateral portions secured to the inner liner and a rearward portion extending rearwardly of said lateral portions. 
     United States Published Patent Application No. 2007/0220663 for HEAD PROTECTOR FOR INFANTS, SMALL CHILDREN, SENIOR CITIZENS, ADULTS OR PHYSICALLY DISABLED INDIVIDUALS published Sep. 27, 2007 upon application by Brooke Picotte teaches a protective hat having a cap member and one or more flexible, resilient shock absorbent pads. The cap member may be constructed so as to fully enclose and/or encapsulate the one or more pads. 
     U.S. Pat. No. 7,841,025 for JAW PAD COVER issued Nov. 30, 2010 to Joshua M. Fink et al. discloses a jaw pad cover for expandably conforming to a shape of a jaw pad for protectively covering the jaw pad of a headgear. The jaw pad cover has a stretchable material blank having a first section and a second section joined together with a stitch. 
     None of the patents nor the published patent application, taken singly, or in any combination is seen to teach or suggest the novel spider web protective structures of the present invention. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention there is provided one or more spider web-like structure formed from a fine but strong polymeric fiber. The one or more spider web structures are spaced apart one from another as well as from any conventional padding foam lining the hard shell of a helmet. The web layer or layers is/are independently attached to the helmet shell, generally at the perimeter edge of the spider wed structures. The innermost web layer surrounds and conforms to a wearer&#39;s head. The use of the inventive web layers allows the production of fewer helmet sizes while still resulting in a perfect conformal fit to a wide range of head sizes and/or shapes within a particular helmet size. Helmets may, therefore, be provided in only a few sizes, each helmet size accommodating a broad range of head sizes and/or shapes. 
     It is, therefore, an object of the invention to provide a protective helmet incorporating one or more spider web-like structures spaced apart from one another and from other padding components. 
     It is another object of the invention to provide a protective helmet incorporating one or more spider web-like structures wherein each spider web-like structure is independently attached to the hard outer shell of the helmet. 
     It is an additional object of the invention to provide a protective helmet incorporating one or more spider web-like structures where two spider web-like structures are spaced apart from one another a distance in the range of approximately one inch. 
     It is a further object of the invention to provide a protective helmet incorporating one or more spider web-like structures wherein an inner spider web-like structure surrounds and conforms to the outside of the head of a wearer of the helmet. 
     It is a still further object of the invention to provide a protective helmet incorporating one or more spider web-like structures utilize fastening systems that allow any spider web structure to be selectively removed from the protective helmet. 
     It is yet another object of the invention to provide a protective helmet incorporating one or more spider web-like structures to provide a fastening system to permanently secure the spider web structures within the protective helmet. 
     It is an additional object of the invention to provide a protective helmet incorporating one or more spider web-like structures that use resilient tethers disposed between an outside surface of the one or more spider web structure and an inner surface of the protective helmet. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Various objects, features, and attendant advantages of the present invention will become more fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein: 
         FIG. 1  is an exploded, perspective, schematic view of a first spider web structure of the invention shown adjacent a helmet shell and poised for insertion thereinto; 
         FIG. 2  is a perspective, schematic view of the spider wed structure of  FIG. 1  installed on the head of a helmet wearer; 
         FIG. 3  is a side elevational, cross-sectional, schematic view of the spider web structure of  FIG. 1  installed in the helmet of  FIG. 1 ; 
         FIG. 4  is an exploded, perspective, schematic view of the spider web structure of  FIG. 1  surrounded by a second, outer spider web structure, both poised for insertion into a helmet; 
         FIG. 5  is a side elevational, cross-sectional, schematic view of the spider web structures of  FIG. 4  inserted into a helmet; and 
         FIGS. 6   a  and  6   b  are side, elevational, schematic view of a mechanism for attachment to an inside surface of a helmet to secure a distal end of a resilient tether thereto in a locked and an open configuration, respectively. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The present invention provides a protective element consisting of one or more spider web structures for use in protective headgear. The spider web structure(s) replace conventional internal padding. For simplicity, the term “football helmet” will be used hereinafter to refer to any type of protective headgear typically using internal padding to protect the head and or neck of a wearer thereof from bodily injury from external impact to the head and/or upper neck. While a football helmet has been used for purposes of illustration and disclosure, it will be recognized that the spider web structures of the invention may be modified to work with virtually any protective helmet. 
     The protective “padding” and restraint element of the invention consists of a first spider web-like structures conformally surrounding a wearer&#39;s head, surrounded by a second, spider web-like structure spaced apart therefrom. The first and second spider web structures surround and envelope the head of a wearer of a helmet incorporating the web structures. Such web structures may be formed from a relatively new product, artificial spider web silk. Artificial silk has both great strength and flexibility. 
     While humans have relied on silk for more than 2,000 years, scientists have herebefore not been able to unravel the mystery of how spiders and silkworms produced their strong fibers. Researchers have now discovered the mechanism for producing strong natural silk, providing critical new information about nature&#39;s strongest fiber. Spider silk is among the toughest materials known, but it is not entirely unique. It is merely one of the most dramatic examples of a sizable family of biopolymers that can teach much about how to improve upon man-made products. In many cases the biopolymers possess a combination of properties that synthetic materials cannot yet provide. Basically, the concept is to copy, to the extent possible, the way that nature manufacturers products (i.e., biosynthesis). Artificial spider web silk is an excellent example of such a man-made material. The polymeric component materials existing at the time of the first invention of artificial spider silk were Kevlar® and nylon. Kevlar® is a strong but inflexible para-aramid synthetic material while nylon is a polyamide synthetic material that is flexible but not very strong. It will be recognized that ongoing research is expected to provide even stronger, more flexible artificial silk materials in the future. Consequently, the invention is not considered limited to the Kevlar®/nylon blend used for purposes of disclosure. Rather, the invention is intended to include any artificial or natural fiber exhibiting properties of strength and flexibility allowing web or net structures to be formed therefrom. 
     One or more web structures, typically spaced apart from one another may be incorporated into a helmet. Typically, the first, inner web structure contacts the head of the helmet wearer. When more than one web structure is incorporated into the helmet, a second web surrounds the first web and is spaced apart therefrom. Each web structure is independently attached, typically removably attached, to the outer hard helmet shell or to some fitting directly attached thereto. 
     Referring first to  FIG. 1 , there is shown a perspective, exploded view of a typical inner web structure poised for insertion into a modified conventional helmet of the prior art, generally at reference number  100 . 
     Web structure  100  typically consists of a plurality of small “spider webs”  102   a ,  102   b  . . .  102   n  held together at their edges. As may readily be seen in  FIG. 1 , each spider web  102   a ,  102   b  . . .  102   n  mimics a web formed in nature by a silk-spinning spider. Typically, a natural spider web has a number of spaced apart strands radiating outward from a central point of the web connected together by a series of spaced apart strands, typically forming polygonal figures of ever increasing size but centered on the central point. Web structure  100  may be constructed from any desired number of spider webs  102   a ,  102   b  . . .  102   n  and spider webs  102   a ,  102   b  . . .  102   n  may be all of one size or, in alternate embodiments spider webs  102   a ,  102   b  . . .  102   n  may be of different sizes. Each of spider webs  102   a ,  102   b  . . .  102   n  is ideally made from an artificial silk material. 
     Regardless of the configuration of spider webs  102   a ,  102   b  . . .  102   n , web structure  100  is constructed to be somewhat smaller than the head  104  of an intended wearer, best seen in  FIG. 2 . The resiliency of web structure  100  will accommodate a wide range of head  104  sizes. It will be recognized that human head  104  forms no part of the present invention and is included merely to illustrate we structure  100  in its intended operating environment. 
     Holes  106  may be left in web structure  100  as required to accommodate a helmet feature, none of which are shown. 
     All or some of the perimeter edge  108  of web structure  100  may be reinforced with bias tape (sometimes referred to as bias binding)  110  or another reinforcing edge treatment. One method for attaching bias tape  110  to web structure  100  is by folding bias tape  110  over perimeter edge  108  and then stitching through both a front and rear layers of bias tape  110  along a major axis of bias tape  110 , thereby trapping and securing perimeter edge  108  therebetween. Both bias tape  110  and its installation are believed to be well known to those of skill in the art. Consequently, neither is further described nor discussed herein. 
     A perimeter edge  108  reinforced with bias tape  110  or a similar structure provides many options for connecting web structure  100  to an appropriate inside surface  112  of a football helmet  114 . It is preferable but not necessarily mandatory that web structure  100  be removably installed in football helmet  114 . The use of connecting elements  116  such as snaps, one or more zippers, a hook-and-loop fastening system, or other similar fastening elements allows installation and removal of web structure  100 . If removability of web structure  100  from helmet  114  is not required, a permanent fastening method such as an adhesive, stitching, ultrasonic welding, or any other suitable permanent fastening system, none of which are shown, but all believed to be known to those of skill in the art may be utilized. 
     Referring now to  FIG. 3 , there is shown a side elevational, cross-sectional, schematic view of web structure  100  installed in a football helmet  114 . While it is anticipated that web structure  100  may be retained in helmet  114  only by its perimeter edge  108 , it is possible that for some applications or for some types of helmet that additional interconnections to helmet  114  will be required. Such connections are generally resilient tethers  118  having a proximal end  120  connected to the surface of web structure  100  at any desired point on its outer surface. A distal end  122  of resilient tether  118  may be connected to an inside surface  112  of helmet  114  by receptacles  126  as best seen in  FIGS. 6   a  and  6   b . Resilient tethers  118  may be used to hold a selected portion of web structure  100  in a predetermined spatial relationship to helmet  114 . Resilient tethers  118  are ideally formed from artificial spider silk because of the mechanical properties thereof already discussed. It will be recognized, however, that other resilient materials may be substituted. Consequently, the invention is not considered limited to the artificial spider silk chosen for purposes of disclosure. Rather, the invention in intended to include any other suitable material. 
     An air gap  132  is formed between web structure  150  and an inner surface  112  of helmet  114 . 
     The embodiment of the invention shown in  FIGS. 1 ,  2 , and  3  includes only a single spider web structure  100 . While highly advantageous when compared to conventional padding of the prior art, it may be desirable to add a second, spaced apart outer spider web structure  150 . Referring now also to  FIG. 4 , there is shown an exploded, perspective, schematic view of the spider web structure  100  and the football helmet  114  of  FIG. 1  with an intervening artificial spider silk outer web structure  150 . 
     Unlike spider web structure  100 , outer spider silk structure  150  is a basket-like structure formed by vertical bands  152   a ,  152   b - 152   n  of artificial silk. Horizontal artificial spider silk cross bands  154   a ,  154   b  . . .  154   n  are attached to vertical artificial spider silk bands  152   a ,  152   b - 152   n  at their intersections therewith. The designation  152   x  is used to designate any one of vertical bands  152   a - 152   n    
     Ends of vertical artificial spider silk bands  152   a ,  152   b - 152   n  are typically removable attached to perimeter  108  of spider web structure  100  and, subsequently to football helmet  114  as described hereinabove. However, to retain a spaced apart relationship to spider web structure  100 , resilient tethers  118  are required. 
     Referring now also to  FIG. 5 , there is shown a side elevational, cross-sectional, schematic view of spider web structure surrounded by outer artificial silk structure  150  installed in football helmet  114 . Resilient tethers  118  are permanently connected to outer artificial spider silk structure  150  at their proximal ends  120 . If outer artificial spider silk structure  150  is permanently attached to football helmet  114 , then distal ends  122  of resilient tethers  118  may be permanently connected to an inner surface of football helmet  114 . However, if outer artificial spider silk structure  150  is designed to be removably attached to football helmet  114 , then a disconnectable attachment mechanism  124  must be used to connect distal ends  122  of resilient tethers  118  to football helmet  114 . 
     Refer no also to  FIGS. 6   a  and  6   b . In one embodiment of such a disconnectable attachment, a ball  124  may be integrally formed at distal end  122  of resilient tethers  118 . Ball  124  may then be received and retained in a spring loaded receptacle  126  with a safety lock  130  to prevent accidental release of ball  124 . Receptacle  126  may be affixed to an inside surface  112  of helmet  114  with a strong adhesive, ultrasonic welding, or any other suitable attachment process material, none shown: Such materials and processes are believed to be well known to those of skill in the art and, consequently, are not further described or discussed herein. 
     In  FIG. 6   a , ball  124  is poised for inserting into receptacle  126 . In  FIG. 6   b , ball  124  is positioned within receptacle  126  and safety lock  130  is in a closed, locked orientation. 
     It will be recognized that numerous alternative designs of an attachment such as a spring loaded receptacle may be substituted therefor. Consequently, the invention is not considered limited to the particular attachment (i.e., spring loaded, locking receptacle chosen for purposes of disclosure. Rather, the invention is intended to include any and all suitable devices for retaining a distal end of resilient tether  118  to football helmet  114 . 
     Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention. 
     Having thus described the invention, what is desired to be protected by Letters Patent is presented in the subsequently appended claims.