Abstract:
A fit system positionable adjacent interior portions of a helmet and cranial surfaces of a cranium of a wearer of the helmet proximate the interior portions of the helmet for improving the fit of the helmet to the cranium. The system includes an elongate fluid impervious bladder having a first end including an inlet port in fluid communication with the bladder and a second end remote from the first end. The bladder defines a single continuous fluid flowpath between the first end and the second end for receiving fluid introducible into the bladder through the inlet port for expanding the bladder so that substantially the entire length of the bladder may be expanded to engage mutually facing portions of the cranium of the user and interior portions of the helmet. The bladder is positionable within the helmet so as to substantially wrap around side portions of the cranium, temple areas of the cranium, a rear occipital protuberance portion of the cranium and an upper portion of the cranium without compromising the fluid flow path.

Description:
CROSS REFERENCE TO RELATED APPLICATION. 
     This application is a continuation of co-pending application Ser. No. 09/586,123, filed Jun. 20,2000, and entitled HELMET FITTING SYSTEM now U.S. Pat. No. 6,351,853, which is a continuation-in-part of U.S. application Ser. No. 09/326,418, filed Jun. 4, 1999, and entitled HELMET FITTING SYSTEM, now U.S. Pat. No. 6,178,560. 
    
    
     FIELD OF THE INVENTION 
     This invention relates generally to helmets and more particularly to a device and method for fitting helmets to the craniums of users. 
     BACKGROUND AND SUMMARY OF THE INVENTION 
     Helmets, such as football helmets often include a high impact polymer shell and a shock absorbing component interior the shell. For mass produced helmets, the shells and shock absorbing components typically are provided in standard sizes, e.g., small, medium and large. To account for variances in head or cranium size, shape and the like within a size, a fitting component may be provided to adjust the fit of the helmet. 
     The present invention relates to an improved fitting component that overcomes disadvantages of prior fitting components and offers improved fit, comfort and ease of use for the user. 
     Accordingly, it is an object of the invention to provide a system for fitting of helmets to craniums. 
     Another object of the invention is to provide a system of the character described that is of one piece construction. 
     An additional object of the invention is to provide a system of the character described that enables custom fitting for individual users. 
     Yet another object of the invention is to provide a system of the character described that can be manufactured from a blank yet which enables fluid to be introduced via a flow path that does not become blocked or otherwise obstructed when the fit system is positioned about the cranium of a user. 
     A further object of the invention is to provide a system of the character described that enables fluid to be introduced via a single flow path for expanding the fit system a desired amount. 
     A still further object of the invention is to provide a system of the character described that enables fluid to be introduced via one or more discrete flow paths for expanding the fit system a desired amount. 
     It is another object of the invention to provide a helmet that incorporates fit systems in accordance with the invention and methods for fitting such helmets to users. 
     A further object of the invention is to provide a fit system of the character described that is uncomplicated in configuration and convenient to use. 
     With regard to the foregoing, the present invention is directed to a fit system positionable adjacent interior portions of a helmet and cranial surfaces of a cranium of a wearer of the helmet proximate the interior portions of the helmet for improving the fit of the helmet to the cranium. 
     The system includes an elongate fluid impervious bladder having an inlet end including an inlet port in fluid communication with the bladder and a terminal end distal from the inlet end. The bladder defines a single continuous fluid flowpath between the inlet end and the terminal end for receiving fluid introducible into the bladder through the inlet port for expanding the bladder so that substantially the entire length of the bladder may be expanded to engage portions of the cranium of the user and interior portions of the helmet. 
     In another aspect, the fit system includes an elongate pliable member that is substantially M-shaped when positioned in a planar orientation and positionable in a non-planar relationship within a helmet so as to substantially wrap around side portions of the cranium, temple areas of the cranium, a rear occipital protuberance portion of the cranium and an upper portion of the cranium. 
     The invention also provides a blank for manufacture of the fit system and having a first fluid impervious sheet material overlying a second fluid impervious material, with selected substantially continuous portions of the first and second sheet materials being sealed together to define a single fluid path that provides an elongate substantially M-shaped cavity for receiving a fluid for expanding the cavity. 
     In still another aspect, the invention provides a method of fitting a helmet to a cranium. 
     In a preferred embodiment, the method includes the steps of providing a helmet comprising a shell having a shock attenuation liner adjacent an interior portion of the shell and a fit system adjacent the interior portion for contacting portions of the cranium. The fit system includes an elongate fluid impervious bladder having a first end including an inlet port in fluid communication with the bladder and a second end remote from the first end. The bladder defines a single continuous fluid flowpath between the first end and the second end for receiving fluid introducible into the bladder through the inlet port for expanding the bladder to engage adjacent portions of the cranium of the user and interior portions of the helmet. The bladder is positionable within the helmet so as to substantially wrap around portions of the cranium without compromising the fluid flow path. 
     Next, the helmet is positioned on the cranium of the user such that the fit system substantially wraps around portions of the cranium without compromising the fluid flow path. Fluid is then introduced into the bladder via the inlet port to desirably expand the fit system to engage adjacent portions of the cranium of the user and the liner of the helmet. 
     In still another embodiment, the invention relates to a fit system including a pair of elongate fluid impervious bladders. Each bladder includes a first end including an inlet port in fluid communication with the bladder and a second end remote from the first end. Each bladder defines a single continuous fluid flowpath between the first end and the second end for receiving fluid introducible into the bladder through the inlet port for expanding the bladder so that substantially the entire length of the bladder may be expanded to engage portions of the cranium of the user and interior portions of the helmet. 
     The invention advantageously enables fitting a helmet to a cranium of a user to enhance comfort and aids in maintaining the helmet desirably positioned on the cranium of the user. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above and other features and advantages of the present invention will become further known from the following detailed description considered in conjunction with the accompanying drawings in which: 
     FIG. 1 is top plan view of a fit system in accordance with a preferred embodiment of the invention. 
     FIG. 2 is a bottom plan view of the fit system of FIG.  1 . 
     FIG. 3 is a cross-sectional end view of the fit system of FIG.  1 . 
     FIG. 4 is a top plan view of a blank for providing the fit system of FIG.  1  and FIG. 5 is a cross-sectional view taken along line  5 — 5  of FIG.  4 . 
     FIG. 6 is an exploded perspective view showing a fit system according to the invention and a cranium. 
     FIG. 7 is a perspective view showing a fit system according to the invention installed within a helmet shell. 
     FIGS. 7 a  and  7   b  show positioning of ports associated with the fit system relative to the shell of a helmet. 
     FIGS. 8 and 8 a  are top plan views of fit system in accordance with the invention having circulating fluid. 
     FIG. 9 is a perspective view showing a fit system according to another embodiment of the invention. 
     FIG. 10 is a bottom plan view showing the fit system of FIG. 8 installed within a helmet shell. 
     FIGS. 11-15 are plan views of alternate embodiments of fit systems in accordance with the invention having a single fluid flow path. 
     FIGS. 16-20 plan views of alternate embodiments of fit systems in accordance with the invention having plural fluid flow paths. 
    
    
     DETAILED DESCRIPTION 
     FIGS. 1-8 
     With initial reference to FIGS. 1-3, there is shown a fit system  10  for use with a helmet for fitting an interior portion of the helmet to a cranium of a user to reduce slippage between the cranium of the user and the helmet, to assist in maintaining the helmet in place on the cranium and to avoid discomfort to the user. The fit system  10  enables a medium to be introduced in a fluid state to void spaces between the interior of the helmet and the cranium to fill or partial fill the void spaces as desired. The medium is flowably introduced through a single, serpentine flow path located between the interior of the helmet and the cranium of the user while the helmet is worn on the cranium. The configuration of the flow path enables a substantially equal pressure to be exerted by the fluid against the cranium of the user regardless of the area of the flow path at a given location of the flow path. 
     The fit system  10  preferably includes a first portion  12  of a fluid impervious material overlying a second portion  14  of a fluid impervious material. The first layer  12  and the bottom layer  14  are preferably made of a relatively flexible and fluid impervious plastic sheet material, such as vinyl. 
     The first portion  12  and the second portion  14  are fixedly attached to one another to provide a substantially impervious bladder  18  therebetween for receiving a fluid. The fluid is preferably either a gas such as air, gels, liquids such as water, or curable liquids, such as a liquid-based foams that cure or set into a solid form, such as polyurethane foam 
     As shown in FIG. 3, the first portion  12  preferably has a thin layer  16  of a soft material exterior to the bladder, such as nylon, velo, moleskin, or other soft, flexible fabric, secured thereto as by adhesive for contacting the cranium of the user. 
     An inlet port  20  is located at an inlet end  22  of the bladder  18  for introducing fluid into the bladder  18 . An outlet port  24  is preferably provided at a outlet or terminal end  26  of the bladder  18  when a curable liquid fluid is to be introduced into the bladder  18  for enabling the fluid to flow out of the bladder  18  during filling. For example, a liquid foam is preferably flowed through the bladder  18  from inlet end  22  to outlet end  26  until fluid is observed to flow out of the port  24 . The presence of fluid exiting the bladder through the port  24  indicates that the bladder is substantially uniformly expanded with the fluid. 
     In the use of non-setting fluids, e.g., gas, gels and liquids that do not change state and maintain their fluidity, the outlet port  24  is preferably not included or is provided with a seal and the inlet port  20  preferably includes a suitable valve arrangement that enables fluid to be introduced into the bladder  18  through the port and to inhibit introduced fluid from exiting the bladder  18  back through the port  20 . 
     The fit system  10  may be manufactured using a blank  27  as shown in FIG.  4 . Sheets  28  and  30  of material representing portions  12  and  14 , respectively are placed in an adjacent orientation. A seal, such as a heat seal, is applied to a selected continuous region of the sheets to bond facing portions of the sheets together in a sealing relationship that defines a seal or border  32  that surrounds a cavity area  34 . The cavity area  34  defines the bladder  18 . Material surrounding the border  32  or material of the border  32  may be trimmed, as by cutting along dashed line  36  or dashed line  38 , to remove excess material as desired. 
     Returning to FIG. 2, the bladder  18  of the fit system  10  defines a single, uninterrupted flow path (defined by arrows  40 ) extending between inlet  20  and outlet  24 . The path defined by the arrows  40  traverses a plurality of individual and interconnected segments, such as segments  42   a - 42   t , configured in a generally “M”-shaped arrangement when the bladder  18  is lying in a plane. 
     The configuration of the fit system  10  and its interconnected segments  42   a - 42   t  advantageously enables a single flow path that can be adapted to be positioned in a non-planar relationship without creasing or bending so as to compromise the flow path. That is, the interconnected segments  42   a - 42   t  cooperate with one another and enable the bladder  18  of the fit system  10  to be positioned about the cranium of the user and within the helmet and to receive fluid and expand the bladder  18 , with the fluid pressure within the bladder being substantially uniform in each of the segments  42   a - 42   t.    
     In this regard, it will be understood that the fit system  10  may have a greater or less number of segments depending on the size of the overall fit system and the size of each segment. That is, each segment may be smaller such that a greater number of segments is required to provide a fit system of desired size or each segment may be larger so that fewer segments are needed. The segments are preferably of substantially uniform size (and volume), however, it will be understood that segments of varying size may be utilized in conjunction with one another. 
     With additional reference to FIGS. 6 and 7, the fit system  10  is configured for placement within an interior portion of a helmet, such as football helmet  50  for receiving a portion of a cranium  52  of a user. As oriented in FIG. 6, the fit system  10  has been placed desirably for placement about the cranium  52 . The flow path, represented by arrows  40 ′ is continuous and placement of the fit system  10  about the cranium  52  has not resulted in creases between segments or other blockage to flow. 
     The helmet  50  preferably includes a shell  70  having ear holes  72  and a shock attenuation liner  74  adjacent an interior portion of the shell  70 . A face mask  76  is also preferably mounted to the shell  70 , as by fasteners. The liner  74  may be secured to the interior of the shell  70  as by adhesive or mating hook and loop material or other fastening means. The fit system  10  is secured to the liner  74 , preferably releasably secured as by hook and loop material, with the layer of soft material  16  positioned for contacting the cranium of a user. 
     As will readily be apparent to one of ordinary skill in the art, the ports  20  and  24  (and any valves associated therewith) may be positioned so as to be located outside of the shell  70  of the helmet for ease of access when the helmet is worn by a user. For example, the lengths of tubing or other material used to provide the ports  20  and  24  may be of sufficient length to extend downwardly below the lower edge of the helmet (FIG. 7 a ) or to extend through apertures  77  and  78 , respectively located through the shell  70  of the helmet (FIG. 7 b ). 
     The fit system  10  substantially wraps around the sides, temple areas  58  of the cranium, above ears  59 , the rear occipital protuberance portion  60  of the cranium and an upper or crown portion  62  of the cranium  52 . Upon introduction of fluid into the bladder  18 , the fluid will travel along the flow path  40 ′ and expand the bladder  18  so that it substantially occupies void areas or gaps between the cranium and adjacent interior surfaces of the helmet. Contact of the fit system with the occipital protuberance  60  tends to urge the fit system and hence the entire helmet in a generally downward direction so as to draw the interior of the helmet closer to the cranium of the user. 
     The following designations referenced in the drawings with regard to portions of the fit system  10  identify particular portions of the cranium to be contacted by the fit system when installed: 
     
       
         
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 TP 
                 Temples 
               
               
                   
                 AE 
                 Above ear 
               
               
                   
                 UOR 
                 Under occipital protuberance in the rear 
               
               
                   
                 CR 
                 Crown 
               
               
                   
                   
               
             
          
         
       
     
     Accordingly, it will be appreciated that the fit system  10  may be advantageously used to fit a helmet to a cranium of a user to enhance comfort and to aid in maintaining the helmet desirably positioned on the cranium of the user. In a preferred embodiment, the fit system  10  may be used to custom fit the helmet to the user. This may be accomplished by first placing the helmet system  70 , with the fit system  10  substantially void of fluid, on the cranium of the user. Fluid may then be introduced into the fit system via the inlet port  20  to desirably expand the fit system so that substantially the entire length of the fit system engages mutually facing portions of the cranium of the user and the liner  74  of the helmet. 
     A desirable fit is achieved when the bladder is sufficiently expanded such that the user experience a snugness of the helmet against the cranium without feeling significant discomfort. In the case of non-curable fluids, such as air and water and the like, a valve mechanism associated with the port  20  inhibits the introduced fluid from exiting the bladder such that the desired pressure achieved by introducing the fluid is maintained. It will be understood that more or less fluid may be introduced and/or subsequently added or removed as desired. 
     When the introduced fluid is a curable liquid, such as a liquid-based foam that cures or sets into a solid form, the fluid is flowed into the bladder via the port  20  until fluid exits the bladder via the port  24 . At that point, the flow of fluid is ceased and the user maintains the helmet in the desired position for several minutes while the fluid cures into a solid form. The curable liquid therefore provides a custom fit that maintains its shape substantially indefinitely. 
     FIGS. 8 and 8 a  shows another embodiment of a fit system  80  in accordance with the invention. The fit system  80  is configured similar to the fit system  10 , except that it includes tubing  82  and  84 . In FIG. 8, one end of the tubing  82  is in fluid communication with the port  20  and one end of the tubing  84  is in fluid communication with the port  24 . The opposite ends of tubing  82  and  84  connects to a circulator  86  for circulating fluid through the fit system. 
     For example, when the fluid is water, the circulator is preferably a water pump for recirculating the water through the flow path for cooling purposes. The water pump may be of conventional pump construction and may be a small, battery powered unit that can be worn while the helmet is in use. A temperature control unit  88 , such as a conventional chiller or heater or heat exchanger, may also be incorporated in-line with the circulator for maintaining the fluid at a desired temperature. During cold weather, it is desirable to heat the fluid and in hot weather to cool the fluid. As will be appreciated, the circulator and the temperature control unit may be remote from the helmet, with the fluid traveling from the remote location to the helmet via tubing or other flow conduits placeable in flow communication with the ports  20  and  24 . 
     Alternatively, as shown in FIG. 8 a , the exit end of conduit  84  may be free to the atmosphere and the circulator  86  provided as by a source  90  of chilled or heated water for feeding a continuous supply of water through the system. 
     FIGS. 9-10 
     Turning now to FIGS. 9 and 10, there is shown an alternate embodiment of a fit system  100  having a shape generally conforming to that of the fit system  10  but of solid construction. For example, the fit system  100  may be made as by flowing foam through the blank of FIG. 4, letting the foam set and thereafter removing all of the material surrounding the set foam to yield a series of interconnected foam segments  102   a - 102   x , with each adjacent segment being connected by a connecting portion  104 . The segments  102   a - 102   x  are preferably secured, as by adhesive, to a flexible backing material  106 . 
     As shown in FIG. 10, the fit system  100  may be incorporated (in the manner of the fit system  10 ) into a helmet system  108  having a shell  110  and a shock attenuation system or liner  112 , with the backing material  106  being secured, as by hook and loop material, to the liner  112 . 
     A preferred shell and shock attenuation system are described in U.S. application Ser. No. 09/325,827, now U.S. Pat. No. 6,219,850 naming as inventors P. David Halstead, Cherie F. Alexander and Thad Ide, filed on Jun. 4, 1999, and entitled HELMET, the entire disclosure of which is incorporated by reference. 
     FIGS. 11-20 
     Turning to FIGS. 11-20, there are shown various additional embodiments of fit systems in accordance with the invention. The following designations referenced in the drawings with regard to portions of the fit systems identify particular portions of the cranium to be contacted by the fit system when installed: 
     
       
         
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 TP 
                 Temples 
               
               
                   
                 AE 
                 Above ear 
               
               
                   
                 UOR 
                 Under occipital protuberance in the rear 
               
               
                   
                 CR 
                 Crown 
               
               
                   
                 MR 
                 Middle of rear 
               
               
                   
                 FR 
                 Front/forehead 
               
               
                   
                   
               
             
          
         
       
     
     The embodiments shown in FIGS. 11-15 have single fluid paths and the embodiments of FIGS. 16-20 have a pair of discrete single flow paths. Each of the fit systems of FIGS. 11-20 is constructed similarly to the fit system  10  in that they are configured to provide a substantially impervious bladder for receiving a fluid. 
     FIG. 11 shows a fit system  120  having a single flow path indicated by arrows  122  between an inlet port  124  and an outlet port  126 . FIG. 12 shows a fit system  130  having a single flow path indicated by arrows  132  between an inlet port  134  and an outlet port  136 . FIG. 13 shows a fit system  140  having a single flow path indicated by arrows  142  between an inlet port  144  and an outlet port  146 . FIG. 14 shows a fit system  150  having a single flow path indicated by arrows  152  between an inlet port  154  and an outlet port  156 . FIG. 15 shows a fit system  160  having a single flow path indicated by arrows  162  between an inlet port  164  and an outlet port  166 . 
     FIG. 16 shows a fit system  170  having a pair of discrete single flow paths indicated by arrows  172  and  173  between inlet ports  174 ,  175  and outlet ports  176 ,  177 , respectively. FIG. 17 shows a fit system  180  having a pair of discrete flow paths indicated by arrows  182  and  183  between inlet ports  184 ,  185  and outlet ports  186 ,  187 , respectively. FIG. 18 shows a fit system  190  having a pair of discrete flow paths indicated by arrows  192  and  193  between inlet ports  194 ,  195  and outlet ports  196 ,  197 , respectively. FIG. 19 shows a fit system  200  having a pair of discrete flow paths indicated by arrows  202  and  203  between inlet ports  204 ,  205  and outlet ports  206 ,  207 , respectively. FIG. 20 shows a fit system  210  having a pair of discrete flow paths indicated by arrows  212  and  213  between inlet ports  214 ,  215  and outlet ports  216 ,  217 , respectively. 
     The foregoing description of certain embodiments of the present invention has been provided for purposes of illustration only, and it is understood that numerous modifications or alterations may be made in and to the illustrated embodiments without departing from the spirit and scope of the invention as defined in the following claims.