Abstract:
A neck collar interfacing with a lower edge of a helmet of a wearer. The collar includes a pad and a shell. The pad is formed of a closed-cell foam material and forms a loop to be secured about the neck of the wearer. A plurality of shell components are secured to portions of the upper face of the pad. The shell is more rigid than the pad to spread the energy of impact with a lower edge of the helmet over a larger region of the pad. The shell and pad each include a chest portion having a split for opening the pad for putting the collar on and taking it off. The shell components are discontinuous at at least one lateral portion of the pad to allow flexibility of the pad for separation of the pad at the split.

Description:
FIELD OF THE INVENTION 
     This invention relates generally to protective gear for sports and, more specifically, to protective neck collars and braces for use by those wearing helmets. 
     BACKGROUND OF THE INVENTION 
     Protective gear for participants in various activities such as motorsports has been standard for years. Motocross riders, for example, are accustomed to wearing head-to-toe protective gear, including a helmet, a neck collar, a chest or roost protector, spine protection, hip and tailbone pads, knee braces or at least pads, and protective boots. This gear has resulted in a significant reduction in injuries to the wearers. However, while a helmet is usually the most cited or recognizable item of protective gear and while it protects the head of the user, it can worsen injuries to the neck due to its mass and rigid shell, particularly the lower rim. The mass of the helmet can cause extra force to pull the head back, to the side, or forward. Nevertheless, the helmet has been found to be worthwhile protective piece. 
     If used in conjunction with a neck collar, the helmet&#39;s protective benefits are further improved. Many riders use foam neck collars to absorb impact of the helmet against the body and limit excessive movement of the head so help avoid neck injury. However, the foam does not disperse energy well over a large portion of the body, such that the point of contact with the rigid lower edge of the helmet extends through the foam in a localized portion of the foam injuring the body and potentially still allowing excessive neck strain. 
     Furthermore, the fit of the neck collar may not be optimal for all users. If the collar has a back brace, it may not fit a wide range of wearers, depending on the thickness of the upper body (chest, shoulders, and upper back) of the wearer. An incorrect fitting neck collar may not effectively prevent injury. Or the person may completely omit wearing a collar that is not comfortable. 
     The inventor of the present invention has found that absorption and dispersion of energy in a collar that is comfortable and doesn&#39;t point load the body during impact is important in providing a protective neck collar. The collar must also limit excessive movement of the helmeted head, while allowing necessary freedom of movement for the chosen activity. The neck collars currently available do not seem to provide this combination of benefits. 
     SUMMARY OF THE INVENTION 
     The present invention provides a protective neck collar for use by a person wearing a helmet. The collar includes a pad and a shell. The shell and the pad combine with a back support to provide a neck collar that absorbs and disperses impact loads effectively. The collar also adjustably fits the user and is easy to put on and take off. 
     The pad forms at least a partial loop to surround the neck of the wearer beneath a lower edge of the helmet (such as a full-face helmet). The pad is formed of compressible material and includes an upper face and a lower face. The lower face is positioned for opposing and bearing against the person when worn. The pad is elastic within its normal range of use. A closed-cell foam material is preferably formed into the desired donut shape of the pad. The pad includes a rear shoulder shelf wider than the remainder of the donut shape. This wider region provides for increased energy absorption and increased impact area for the rear of the helmet, upon impact with the rear edge of the helmet. 
     The shell overlies at least a portion of the upper face of the pad. It is formed of a material more rigid than the pad and is situated for at least intermittent contact with the lower edge of the helmet upon use. The helmet impacts the shell, which disperses impact energy to a larger area of softer pad material and over a larger area of the body (shoulders, back, and chest) of the wearer. 
     In a preferred embodiment, the pad includes a front, chest portion that is split such that it forms a right side and a left side that are separable from each other for donning and doffing the collar. The shell also includes a front, chest portion overlying he pad chest portion. The shell chest portion is split with a right side and a left side that are separable from each other for donning and doffing the collar. The shell is plastic composite and is bonded to the pad over portions of the upper surface and sides of the pad. The shell includes a lateral shoulder portion having a gap. The gap opens a portion of the pad from being bonded to the shell along a small region of the pad. This gap allows the chest portion of the collar to move laterally upon flexure of a lateral region of the pad (i.e., at the gap) that is not overlayed with the shell. The shell includes a closure tab between the right and left sides of the chest portion. 
     In one embodiment, the neck collar includes a liner covering most of the lower face of the pad. In an alternate embodiment, the liner also extends upwardly along portions of the inner sides of the pad. The liner is constructed of a molded EVA foam material. The liner overlaps the split between the left and right sides of the pad chest portion. The liner has a fastener to secure the right and left sides of the pad chest portion together. 
     The neck collar further includes a back support brace secured beneath the lower face of the pad at a rear portion of the pad. The back support brace extends down a portion of the back of the shoulders of the person wearing the collar. A rear strut extends between a lower portion of the back support brace and the rear portion of the pad. The rear strut is preferably at least somewhat flexible. The strut absorbs energy upon impact of the collar with the edge of the helmet. In the preferred embodiment, the rear strut is adjustable to change the relative position of the back support brace and the chest portion of the pad. 
     In one aspect of the invention, the neck collar is secured to the wearer with a harness. The harness extends under the arms of the wearer with a clasp in the front. It is also adjustable. 
     As will be readily appreciated from the foregoing summary, the invention provides additional protection for the neck of a person wearing a helmet. The collar includes a pad providing a comfortable interface to the wearer with a shell over portions of the pad to deal with impact from the edge of the helmet and disperse the impact load. In this way the energy of impact is absorbed and user is more comfortably protected. The arrangement is substantially the reverse of the prior-art prophylactic neck collars, which include a somewhat rigid frame with padding on top of the frame opposite the bottom edge of the helmet. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Preferred and alternative embodiments of the present invention are described in detail below with reference to the following drawings. 
         FIG. 1  is a perspective view of the neck collar of the present invention from the top left side; 
         FIG. 2  is an exploded view of the neck collar of  FIG. 1 ; 
         FIG. 3  is a perspective rear underside view of the neck collar from the left side; 
         FIG. 4  is an exploded view of the neck collar of  FIG. 3 , from the right side; 
         FIG. 5  is a plan view of a liner for the neck collar of  FIGS. 1-4 ; 
         FIG. 6  is a perspective view of the collar with the sides flexed open; 
         FIG. 7  is a perspective view of the neck collar and harness on a person; and 
         FIG. 8  is a front elevational view of the neck collar, including the harness. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The present invention comprises a neck collar for use with a helmet to prevent neck injuries from impacts the user may encounter in activities ordinarily carried out with the use of a protective helmet. As shown in  FIGS. 1 and 2 , a neck collar  10  is provided to interface with the lower edge of a helmet to absorb the energy of impact and restrain excessive head movement and whip in an impact to the head or body of the wearer. 
     Neck collar  10  includes a pad  12  and a shell  14 . Pad  12  forms a donut shape that surrounds the neck of the wearer above the shoulders, chest, and upper back. The pad is preferably made of a closed-cell foam material, such as polyurethane. Alternatively, the pad may be constructed of various materials that absorb the impact load as the edge of the helmet strikes the collar. The material also provides comfort to the wearer as the pad can contour to the user as it presses against the user. Elasticity in the pad material is preferable, such that the collar may be used for more than a single substantial impact. 
     Shell  14 , in the preferred embodiment, selectively covers portions of the top of pad  12 . Shell  14  is constructed of a more rigid material than pad  12 , such that it disperses the impact load from the helmet over a broader region of pad  12  as the energy is absorbed. The softer pad material provides a cushion to conform and distribute the load against the user&#39;s shoulders, collar bone, chest, and/or back. In this manner, the energy of impact of the helmet is less likely to injuriously bear on the body of the user. Shell  14  is preferably constructed of plastic material vacuum formed into a shell shape to extend over the top and partially down the sides of pad  12 . Shell  14  is preferably bonded with glue to pad  12 . Shell  14  includes a rear shell portion  14   a , a right shell portion  14   b , and a left shell portion  14   c  extending over a rear recess  15   a , a right recess  15   b , and a left recess  15   c , respectively, of pad  12 . See  FIG. 2 . 
     The recesses  15   a - c  are slight, preferably about the same depth as the thickness of shell  14 , such that the shell fits therein with a smooth exterior transition between pad  12  and shell  14 . The wide rear region of pad  12  and shell  14  allows for good load dispersal as well as a broad impact base to ensure that the edge of the helmet is restrained. 
       FIGS. 3 and 4  illustrate back support  16 . Back support  16  extends downwardly from the rear underside of pad  12  to contact the upper back and shoulder blade region of the wearer to support against the helmet impact on the rear portion of shell  14  and pad  12 . An under-pad structural member  18  is preferably secured to the rear underside of pad  12  within a slight underside recess  19 . Structural member  18  preferably extends substantially directly under rear shell portion  14   a , with a rear portion of pad  12  sandwiched therebetween. Back support  16  is secured to a forward portion of structural member  18 . Back support  16  is braced against folding up by a support strut  20  extending between a rear side of back support  16  and a rear portion of structural member  18 . 
     Support strut  20  is preferably formed of a slightly flexible material to further absorb impact. However, the overall construction of pad  12  and back support  16  may have sufficient energy absorbing properties such that strut  20  may be less flexible and simply transmit loading from structural member  18  to back support  16 . Strut  20 , in some embodiments, also has a shape to provide some degree of flexibility, while still not folding completely so as to provide impact absorption without allowing excessive head movement and neck injury. Support strut  20  includes a pin hole  20   a  for a pin to secure the upper end of strut  20  to structural member  18 . Strut  20  also includes adjustment holes  20   b  (see  FIG. 4 ) at its lower end for adjustable attachment to back support  16 . Various alternate methods and means of adjustable attachment may be employed. For example, a screw adjustment system may be employed. In other embodiments, multiple struts may be used between structural member  18  and back support  16 . 
     Referring more particularly to  FIG. 4 , a back pad  22  is secured within back support  16 . Back support  16  is constructed of a half shell having sides extending forwardly from the back shell portion to provide structural strength and rigidity to the overall support member. Back pad  22  nests within and projects slightly beyond the half shell to increase the comfort to the wearer and absorb energy of impact. 
     In an alternate embodiment, a back liner  24  is secured to back pad  22 , preferably with a hook and loop fastener. Back liner  24  is constructed of an EVA foam material for additional comfort and absorption qualities. In the preferred embodiment, back liner  24  is integrated with back pad  22 . A pad liner  26  is also provided along the underside of pad  12  for the same purposes. Pad liner will be discussed in more detail below in connection with  FIG. 5 . 
     Returning to the interconnection and support for the rear portion of pad  12  and shell  14 , four pivot bosses  28  project downwardly from the underside of structural member  18 . Two pivot bosses  28  extend from the right side of structural member  18  and two extend from the left side. The right and left pivot bosses  28  secure right and left sides of back support  16 , respectively, with a pinned pivotal attachment. Strut bosses  32  extend downwardly from the rear center portion of structural member  18 . Strut bosses  32  secure the upper end of support strut  20  with a pin. The lower end of support strut  20  is secured to back support bosses  34  with a removable pin or other fastener. 
     The preferred pivotal attachment allows back support  16  to be adjusted for the size of the chest and back of the user. Thus, a secure fit can be achieved to reduce undesirable shifting movement of neck collar  10  on the user. Adjustment is carried out in the preferred embodiment of the invention by removal of the pin or fastener securing the lower end of support strut  20  and securement of the fastener in the adjustment hole  20   b  that most closely and comfortably positions back support  16  against the upper back of the wearer. Once the preferred position of the back support member is obtained, the pin is placed in the closest adjustment hole  20   b  in the lower end of support strut  20 . 
     While pad  12  is generally donut shaped, it preferably includes a split front to aid in donning and doffing neck collar  10 . The facing split surfaces include coupler recesses to accommodate a coupler extending from shell  14 . Left shell portion  14   c  includes a coupler tab  42  (see  FIG. 2 ) projecting to the right from the end thereof that covers the split end of pad  12 . Right shell portion  14   b  includes a coupler slot  44  to receive tab  42  and engage therewith. Tab  42  preferably provides a spring detent action to clip within coupler slot  44 . Tab  42  is disengaged from slot  44  by pressing downwardly on the portion nested within left shell  14   c.    
     Securement of the split ends of pad  12  is also carried out by an overlapping portion  46  of pad liner  26 , as seen in  FIG. 5 . Liner  26  forms a ring with overlapping portion  46  being joined to the opposite end of liner  26  with a hook-and-loop fastener  50 . A release tab  42  is secured to the end of liner  26  that overlaps below the other end. This tab can be grasped by the wearer to remove the overlapping connection and open the collar by disengaging coupler tab  42  from coupler slot  44 . 
     Hook-and-loop fastener  50  is also secured to the upper side of liner  26  and the lower side of pad  12  to engage them together. As seen in  FIG. 5 , the lower face of liner  26  includes ridges  52  and recesses  54 . These ridges and recesses aid the comfort of the wearer and provide air circulation under liner  26 . The contours are preferably formed in the EVA material of liner  26  when the liner is formed. 
       FIG. 6  illustrates a flexed open position of neck collar  10 . This is the position the collar is held in to don or doff the collar. The collar is flexed open, placed around the neck of the user, closed, secured with tab  42  and overlapping portion  46 , after which a harness  48  is secured around the back and chest of the wearer below the neck collar and under the wearers arms, with a fastener in front, below the chest portion of pad  12 . See also  FIGS. 7 and 8 . The space between right shell portion  14   b  and rear shell portion  14   a  provides a portion of pad  12  to which a shell material has not been bonded. This region provides a right flex zone  56 . A left flex zone  58  is likewise provided. In alternate embodiments, shell  14  may cover all zones, but may be non-bonded to pad  12  in overlap regions such that pad  12  can flex beneath shell  14  to facilitate the flexure opening of the split ends of pad  12 . Further additional flex zones may alternatively be provided, as long as the shell covers sufficient area on top of the pad to disperse the impact load from the helmet. Note that the lower edge of the helmet will bridge flex zones  56 ,  58  to transfer load across the flex zones and onto the shell portions. 
       FIG. 7  illustrates a user wearing a helmet  62  having neck collar  10  secured in place. Note the positioning of lower edges  64  of helmet  62  adjacent and above the upper faces of shell  14 . Upon an impact situation, such as a motorcycle crash, the head and helmet  62  may be thrust forwards, backwards, and/or sideways. It will then contact shell  14  of neck collar  10 , restraining the head from excessive movement such that neck injury is reduced or avoided. Shell  14  is sufficiently rigid and robust to spread the impact load over a larger area of pad  12  such that it both absorbs energy and spreads the impact load to a larger area of the body of the wearer. Thus, a dangerous concentrated impact on the body is avoided. 
     A neck collar for use by a person wearing a helmet having a lower edge may comprise: (a) a pad forming at least a partial loop, the pad being of compressible material, the pad having an upper face and a lower face, the lower face positioned for opposing the person when worn around a neck of the person; and (b) a shell overlying at least a portion of the upper face of the pad, the shell being formed of a material more rigid than the pad and being situated for at least intermittent contact with a lower edge of the helmet upon use; (c) wherein the pad includes a front, chest portion that is split with a right side and a left side that are separable from each other for donning and doffing the neck collar; (d) wherein the shell includes a shell rear portion and a shell chest portion overlying a pad chest portion, the shell chest portion being split with a right side and a left side that are separable from each other for donning and doffing the neck collar; (e) wherein the right side and left side of the chest portion are separate members from the shell rear portion and gaps are defined between the shell rear portion and the right and left sides of the shell chest portion such that the shell does not cover any portion of the pad along small regions of the pad extending between the right and left sides of the shell chest portion and the shell rear portion, thus allowing the shell chest portion to move laterally upon flexure of the small regions of the pad that are not covered with the shell. The shell chest portion and shell rear portion are separate pieces thus allowing a chest portion of the neck collar to move laterally upon flexure of a small region of the pad between the rear shell portion and chest shell portion. 
     A neck collar for use by a person wearing a helmet having a lower edge, the neck collar may comprise: (a) a pad forming at least a partial loop, the pad being of compressible material, the pad having an upper face and a lower face, the lower face positioned for opposing the person when worn around a neck of the person; and (b) a shell overlying at least a portion of the upper face of the pad, the shell being formed of a material more rigid than the pad and being situated for at least intermittent contact with a lower edge of the helmet upon use; (c) wherein the shell includes a rear shell portion and a chest shell portion, the rear shell portion being a separate member from the chest shell portions and a first gap being defined between a left side of the chest shell portion and the rear shell portion and a second gap being defined between the right side of the chest shell portion and the rear shell portion such that the shell does not cover portions of the pad spanning the first and second gaps from the chest shell portion to the rear shell portion, the first and second gaps being positioned over shoulder portions of the pad, thus allowing the chest shell portion of the neck collar to move laterally upon flexure of the portions of the pad spanning the first and second gaps from the chest shell portion to the rear shell portion, the first and second gaps being positioned over shoulder portions of the pad. 
     While the preferred embodiments of the invention has been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. For example, a fixed rather than pivotal connection of the back support to the pad and shell may be employed. The liner may extend up within the sides of the pad rather than simply along the bottom surface of the pad. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment. Instead, the invention should be determined entirely by reference to the claims that follow.