Patent Publication Number: US-10321724-B2

Title: Personal impact protection device

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority of Provisional Application Ser. No. 61/599,566, filed on Feb. 16, 2012. 
    
    
     FIELD 
     This disclosure relates to an impact protection device that is worn on the person. 
     BACKGROUND 
     Helmets, shoulder pads, thigh pads and other protective gear is used by people in various situations to help protect the body from injury due to impacts. In contact sports such as football, hockey and lacrosse, impacts to the head can be especially problematic. 
     Protective gear typically aims to absorb impact energy through the use of compressive pads. Such pads do absorb some energy, but are not sufficient. One problem is that when pads reach their compression limit they lose effectiveness. Another problem is that only the portion of the pad directly under the impact location, and areas close to the impact location, is compressed, which limits the pad volume involved in energy absorption and thus limits its effectiveness. 
     SUMMARY 
     This disclosure features a personal impact protection device comprising a first mechanical member, a second mechanical member spaced from the first mechanical member, and one or more elastomeric energy-absorption members mechanically coupled to and spanning the distance between both of the mechanical members. The mechanical members may be nested and may be generally concentric. The first mechanical member may comprise a first shell that is constructed and arranged to be placed on the head, and the second mechanical member may comprise a second shell that substantially surrounds and is spaced from the first shell. The impact protection device may further comprise a facemask that is mechanically coupled to the second shell. The energy-absorption members may be thin, flat sheet members or elongated straps. The impact protection device may be, for example, a helmet, a knee protector or a thigh protector. 
     The impact protection device may further comprise one or more energy absorption subassemblies. The energy absorption subassemblies may comprise generally concentric spaced rings comprising an inner ring and an outer ring, and a plurality of the energy-absorption members mechanically coupled to both the inner ring and the outer ring and spanning the distance between the rings. The energy-absorption members that are coupled to the spaced rings may be generally annular. The energy-absorption members that are coupled to the spaced rings may themselves be spaced around at least most of the circumferences of the inner and outer rings. The inner ring may be fixed to the outside of the first mechanical member, and the outer ring may be fixed to the inside of the second mechanical member. The energy-absorption members may be elastomeric strips that are coupled together at one end and free from each other at the other end. Some of the energy-absorption members may be longer than other members. Some of the energy-absorption members may be stronger than other members. 
     The first mechanical member may comprise a first inner ring and the second mechanical member may comprise a first outer ring spaced from and surrounding the first inner ring; a plurality of the energy-absorption members may be mechanically coupled to both the first inner ring and the first outer ring and span the distance between such rings. The impact protection device may further comprise a first shell to which the first outer ring is mechanically coupled. The impact protection may further comprise a second inner ring and a second outer ring spaced from and surrounding the second inner ring, and a plurality of energy-absorption members mechanically coupled to both the second inner ring and the second outer ring and spanning the distance between such rings. The impact protection device may further comprise a second shell to which the second outer ring is mechanically coupled. The first shell and the second shell may be connected by a hinge that is located between the shells. The first shell and the second shell may each be constructed and arranged to be attached to clothing covering a leg, with one shell above the knee and the other shell below the knee and the hinge proximate the knee. 
     Also featured in this disclosure is a helmet comprising a first shell that is constructed and arranged to be placed on the head, a second shell that substantially surrounds and is spaced from the first shell, one or more energy absorption subassemblies located between the first and second shells, each energy absorption subassembly comprising generally concentric spaced rings comprising an inner ring and an outer ring and a plurality of elastomeric energy-absorption members mechanically coupled to both the inner ring and the outer ring and spanning the distance between the rings; the energy-absorption members are spaced around at least most of the circumferences of the inner and outer rings. The inner ring of each energy absorption subassembly is fixed to the outside of the first shell, and the outer ring of each energy absorption subassembly is fixed to the inside of the second shell. 
     Further featured herein is an impact protection device for protection of a knee comprising two energy absorption subassemblies, each energy absorption subassembly comprising generally concentric spaced rings comprising an inner ring and an outer ring, and a plurality of elastomeric energy-absorption members mechanically coupled to both the inner ring and the outer ring and spanning the distance between the rings; the energy-absorption members are spaced around at least most of the circumferences of the inner and outer rings. There is a first housing to which the outer ring of a first energy absorption subassembly is mechanically coupled, and a second housing to which the outer ring of the second energy absorption subassembly is mechanically coupled. The first housing and the second housing are each constructed and adapted to be attached to clothing covering a leg, with one housing above the knee and the other housing below the knee. The first housing and the second housing are connected by a hinge that is located between the housings and proximate the knee. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is a highly schematic cross-sectional representation of a personal impact protection device in the at-rest position. 
         FIG. 1B  is a view of the same device under impact. 
         FIG. 2  is a similar view of an alternative arrangement of a personal impact protection device. 
         FIGS. 3A and 3B  are perspective and top views, respectively, of an energy-absorption subassembly for a personal impact protection device, and  FIG. 3C  is a cross-sectional view taken along line A-A of  FIG. 3B . 
         FIG. 4  is a highly schematic representation of a helmet worn on the head to protect the head. 
         FIGS. 5A and 5B  are schematic side views of the helmet of  FIG. 4  in the at-rest and under-impact positions, respectively. 
         FIGS. 6A, 6B, 6C and 6D  are perspective, side, front, and a second perspective view, respectively, of an impact protection device for protection of a knee. 
         FIG. 7  shows the device of  FIG. 6  in use. 
         FIGS. 8A-8F  are full perspective, hidden-detail perspective, side, top and two cross-sectional views, respectively, of a different helmet design. 
         FIG. 9  is a schematic cross-sectional view of a different helmet design. 
         FIGS. 10A and 10B  are side views of two alternative energy absorption members. 
         FIG. 11  shows a tool that can be used to insert the members shown in  FIGS. 10A and 10B . 
         FIG. 12  is a partial cross sectional view of a protective device using the energy absorption members of  FIGS. 10A and 10B . 
         FIG. 13A  is a partial cross-sectional view of another impact protection device. 
         FIG. 13B  is an end view of a portion of  FIG. 13A . 
         FIG. 13C  is a cross-sectional view taken along line A-A of  FIG. 13A . 
     
    
    
     DESCRIPTION OF EMBODIMENTS 
     The advance set forth in this disclosure may be accomplished in a personal impact protection device. The personal impact protection device uses one or more elastomeric energy-absorption members that are mechanically coupled to two spaced nested mechanical members that act as impact areas, and also act as anchor points and supports for the elastomeric members. One of the two mechanical members is coupled to a person&#39;s body. The coupling can be to clothing worn by the person or directly to the body of the person. The coupling can be accomplished by means such as elastic straps. When the impact protection device undergoes impact to the second or outer member, the second mechanical member (that is not coupled to the body) is moved relative to the first mechanical member. This movement causes the spacing between the members to change: on the side of the members away from the impact, the spacing between the members increases. This causes the elastomeric members located in the region in which the spacing has increased to stretch. As the elastomeric members stretch, they absorb momentum and thus lower the force felt by the person wearing the device. The impact protection device thus helps to protect the person from injury caused by the impact. 
     Personal impact protection device  10  is schematically depicted in  FIGS. 1A and 1B . Device  10  includes outer mechanical member or shell  12  that substantially or fully surrounds, and is spaced from, inner mechanical member or shell  14 . The shells are preferably nested together and they may or may not be concentric. Shells  12  and  14  are sized and shaped and made from a material that is sufficient for the intended application of device  10 . Different applications are described below. Typically, shells  12  and  14  are made from a molded plastic material such as polycarbonate. Device  10  includes one or more elastomeric energy absorption members. In this example, one member  16  provides the compliance and energy absorption functions. Member  16  in this case is a thin, flat piece of elastomeric material that may take the form of a strap or sheet of material. One material may be butyl rubber. Other materials, sizes, shapes and thicknesses are contemplated depending on the overall construction of the impact protection device, the arrangement of and distances between the first and second mechanical members, and the amount of force and the locations and directions of impact that are designed to be ameliorated by the device. 
     Energy-absorption member  16  is anchored to shell  12  at locations  21  and  22  and anchored to shell  14  at location  20 . Upon inwardly-directed impact against shell  12  at or proximate location  26 , shell  12  is pushed in the direction of arrow “A” relative to shell  14 , which is stationary or largely stationary due to it being coupled to clothing or the body. The impact thus increases the distance between the shells at the side opposite the impact location, indicated by increased gap  30 . This motion causes member  16  to stretch, which absorbs energy. In an ideal situation, all of the impact energy is absorbed by member  16 . Even if less than all of the energy is absorbed, the energy absorption decreases the amount of energy transferred to the body in and around area  27  proximate the area of impact  26 . 
     The personal impact protection device can be constructed and arranged to absorb impact energy from all directions and angles, or from less than all. The example shown in  FIGS. 1A and 1B  would do little to absorb impact energy from direction  29  or another direction in which energy-absorption members are folded or compressed as opposed to being stretched, as the elastomeric energy-absorption members will simply bend or fold if they are compressed. This property of relatively thin and elongated elastomeric members can be ameliorated by arranging the one or more energy-absorption members such that they are stretched when the impact protection device is impacted in a particular location and/or direction. As one simple example,  FIG. 2  depicts a personal impact protection device  40  that will absorb energy from impact around the entire circumference of outer member or shell  44 . For impacts at the front area  56 , rear area  55  and the lateral areas  57  and  58 , elastomeric energy absorption member  46  will be stretched and thus absorb energy. This is accomplished by anchoring single elastomeric member  46  at points  47 - 53  to both the inner mechanical member or shell  42  and the outer mechanical member or shell  44 . The same function could be accomplished with a plurality of elastomeric energy-absorption members that are mechanically coupled to both the inner and outer shells and located at locations in which the outer shell will be pushed away from the inner shell upon impact: in other words, in locations other than at the impact or expected impact location. Obviously if impact can be expected at any point around the circumference of the impact protection device, elastomeric energy-absorption members should be spaced around at least most of or all of the circumferences of the inner and outer shells. Other energy absorption means such as traditional compressible cushioning (not shown), can potentially be added, to augment the elastomeric-based energy absorption by locating the cushioning between the energy absorption members at the expected impact areas. 
     The personal impact protection device may include one or more energy-absorption subassemblies. Broadly, an energy-absorption subassembly can be an assembly that carries one or more elastomeric energy-absorption members and that is constructed and arranged to be mechanically coupled to and located between the first and second mechanical members or shells. The energy-absorption subassemblies thus can assist with the ease of manufacturing or assembly of the personal impact protection device. 
     In a non-limiting embodiment shown in  FIGS. 3A-3C , energy-absorption subassembly  60  comprises generally concentric spaced annular rings comprising an inner ring  64  and an outer ring  62 . A plurality of energy-absorption members  66  are mechanically coupled to both the inner and outer ring and span the distance between the rings. In this example, members  66  are annular pieces of elastomeric material. Members  66  can be created, for example, through extrusion, or by cutting an elastomeric tube of the correct diameter into pieces of a desired width. Members  66  can be anchored to the rings or not, can be a desired thickness and width and/or material, and can be located at desired locations and spaced in a desired manner to accomplish a particular amount of energy-absorption at one or more desired locations of the subassembly. For example, stronger elastomers can be placed with some slack such that they begin to stretch only close to the endpoint of travel of the outer ring (or the outer mechanical assembly); this would be useful for heavy impacts that otherwise would cause the rings (or mechanical members) to come into contact and thus prevent further energy absorption. Multiple elastomeric members of different lengths and/or different strengths can be located in parallel so that their energy-absorption is cumulative. 
     The subassembly can be mechanically coupled to the mechanical members/shells in a desired fashion, such as by riveting or using other fasteners. Typically, outer ring  62  would be fixed into the inside of the outer shell, and inner ring  64  would be fixed to the outside of the inner shell. Subassembly  60  thus would establish the gap between the inner and outer mechanical members/shells. 
     The circular subassembly is not necessary. A similar result can be accomplished by using a number of smaller subassemblies each comprising spaced structural members that are adapted to support one or more elastomers, e.g., with one or two elastomers to each subassembly. The subassemblies can be arc-shaped, or can take another shape that is appropriate for the space between shells in which they are to be located. They can be distributed anywhere in the helmet or other personal impact protection device. They can be attached to any helmet of any size using standard mechanical fasteners such as rivets. The elastomer is tubular, like a piece of a bicycle inner tube. The tubes slip over the structural members of the subassembly, and the subassemblies are then attached to each shell. The absorption strength of a subassembly can be changed simply by using a longer tube. The distance between the shells can be any length, say from 1 to 3 inches, using standard parts. A three inch elastomer has nine times the absorption of a 1 one inch elastomer. More generally, subassembly  60  can be divided into individual subassemblies as may be desirable to achieve a particular result. 
     One particular embodiment of the personal impact protection device is a helmet that is constructed and arranged to be worn on the head of a user to protect the head from impact injury. Helmet  70 ,  FIGS. 4 and 5 , comprises first or inner shell  72  that is constructed and adapted to be placed on head  76 . This placement anchors shell  72 , ideally such that it does not move, or at least is constrained from movement in six degrees of freedom. Outer shell  74  is spaced from and substantially surrounds inner shell  72 . In this example, two energy-absorption subassemblies  80  and  82  are located in the space between shells  72  and  74 . Subassemblies  80  and  82  generally have the same construction as subassembly  60 ,  FIG. 3 . If subassembly  80  is located in the helmet around the forehead region, where the helmet encircles the head, it can be fully annular and can have elastomeric energy-absorption members around its entire periphery. Since second subassembly  82  is located in a region of the helmet that has an opening in front of the face, it is not fully annular but is more arc-shaped, encompassing an angle of around 180 to 270 degrees. Face mask  78  is mechanically coupled to outer shell  74 , so that forces on the facemask are transferred to the outer shell and thus cause its motion, which results in forces being dispersed. 
     The operation of helmet  70  is schematically depicted in  FIGS. 5A and 5B .  FIG. 5A  shows a rest position in which there is no impact on the helmet.  FIG. 5B  shows an impact  84  on the left side of helmet  70 . The impact pushes shell  74  to the left, in other words, parallel to the direction of the impact. Since shell  72  is fixed to the head, it does not substantially move. The result is that gap  86  is increased, which stretches all of the elastomeric members of both subassemblies  80  and  82  that are on the right-hand side of the subassemblies, and to some extent, elastomeric members located at the front and rear of the helmet. This absorbs impact energy. Elastomeric members in the area of impact are folded or compressed as indicated by members  91  and  92 ; these contribute little or nothing to energy absorption. 
     Helmet  70  is also able to absorb blows borne from the bottom or top, and oblique blows that cause torque. Any impact that moves the outer ring of an energy-absorption subassembly relative to the inner ring will cause one or more elastomeric members to stretch, and thus absorb energy. Any motion of the outer shell that causes the stretching in any direction of one or more elastomeric members will absorb energy and thus help to ameliorate the effects of impact. 
     A specific embodiment of an impact protection device for protection of a knee, is shown in  FIGS. 6 and 7 . Device  100  in this case comprises two energy absorption subassemblies  102  and  106 . Each such subassembly is mechanically coupled to one of housings  104  and  108 . The housings are interconnected by a pivot or hinge device  110  that allows housings  104  and  108  to pivot about one or more axes that are normal to the surface of hinge  110 . Also, plates  153  and  155  that are directly coupled to hinge  100  are adapted to slide up and down within receiving channels  154  and  156 , respectively, to give housings  104  and  108  the ability to move vertically; this allows for adjustment for comfort and fit, and also allows for greater freedom of movement of the user. In use as shown in  FIG. 7 , pivot  110  is placed proximate knee area  132  of leg  130 . Hinge  100  could be covered by a protective cover or disk (not shown) to help prevent it from being damaged by impacts. Housing  104  is located above the knee, in thigh area  134 . Housing  108  is located below the knee, in calf area  136 . Device  100  is designed to help absorb the energy of impacts to the outside of the knee. 
     Device  100  is worn such that the side with the pivot and that defines a continuous portion of hinged housing assembly  112  is located along the outside as opposed to the inside of the wearer&#39;s knee, where impact is most likely to occur in a sport such as football. The housing assembly helps to transfer force at any location along the length of the assembly to one or both of the energy-absorption subassemblies  102  and  106 . Assemblies  102  and  106  are arranged such that in the rest position shown in the drawings, there is a larger gap between the inner and outer rings on this outside area proximate portion  120  than on the opposite or inside portion  121 . Since the gap in the area of impact defines the maximum travel of the outer ring of the energy-absorption subassembly relative to the inner ring, having the inner and outer rings generally but not exactly concentric as in this case, can provide additional energy absorption in one direction, which in this case is impact to the outside of the knee area that can cause severe injury. 
     Housing  104  can pivot about axis  113 . Housing  108  can pivot about axis  114 . Structure  110  can pivot about axes  113  and  114 . Elastomeric energy-absorption member  103  of subassembly  102  and elastomeric energy-absorption member  107  of energy absorption subassembly  106  are indicated in the drawings. 
       FIGS. 8A-8F  show an alternative helmet design, and illustrates features that can be applied to helmets and other impact protection devices according to this disclosure. Helmet  200  comprises inner shell  204  that sits on the head and surrounding spaced outer shell  202 . Facemask  206  is mounted to outer shell  202 . Energy-absorption subassemblies  201  and  203  in this case each comprise a plurality of separate elastomeric members that are anchored in both shells, such as members  222  and  232 , and as shown in  FIG. 8F  members  251 - 255  of subassembly  201 , and members  261 - 263  of subassembly  203 . 
     In this non-limiting example, each elastomeric member is a flat sheet that fits through slots in both shells. Each has one enlarged end (e.g., ends  220  and  230 ) that sits on either the outside of the outer shell or the inside of the inner shell to prevent the member from being pulled through the adjacent slot. The other ends of the elastomeric members are mechanically coupled to the other shell by a suitable mechanical means, such as clamps  224  and  234 . Also, additional molded rubber or plastic part  208  (with sufficient compliance such that it does not substantially inhibit relative motion of the shells) is coupled to the lower rims of the two shells. Part  208  can potentially add some additional compliance/energy absorption, but mainly part  208  is used to close the opening between the shells to prevent clothing or other objects from entering. 
       FIGS. 10A and 10B  show two similar energy absorption members  402  and  410 . Differences between the two can be their length and/or their strength. Member  402  illustrates the construction with parallel legs  403  and  405  that have perpendicular terminal portions  404  and  406  and distal terminal portion  408 . Members  402  and  410  can be coupled to two spaced shells such as shells  432  and  434  of impact protection device  430 ,  FIG. 12 . The members are pushed through aligned openings in the shells via tool  414 ,  FIG. 11 , which includes blade  416  that is sized and shaped to fit into opening  407  between legs  403  and  405 . The handle  418  is pushed down to force enlarged end  408  through a hole in the inner shell. Upper ends  404  and  406  sit against the outer shell adjacent to the opening. This anchors the member to both shells. As shown in  FIG. 12 , enlarged common end  440  of member  438  will sit against the inside of inner shell  434  while end  442  sits in a recess on the outside of outer shell  432 . Cap  444  can be pushed into the recess to smooth the outside of device  430 . Member  450  is slightly longer than member  438  so it is slack in the at-rest, non-impacted position depicted in  FIG. 12 . Upon impact, member  438  will be stretched and then eventually if the shells are moved sufficiently far apart member  450  can be stretched to absorb more energy. Also, as described above, the different members can be different strengths (e.g., different thicknesses) to provide more variability to the energy absorption characteristics of the protective device. 
     Another example is shown in  FIGS. 13A-13C . Impact protection device  500  includes outer shell  502  and inner shell  504 . Elastomeric spring  510  connects the shells. Spring  510  is a continuous thin elastomeric sheet with ends  561  and  562 . End  562  is fixed to shell  504  while end  561  is free. Spring  510  is threaded over rollers  511 ,  513 ,  515 ,  519  and  521  that are carried by outer shell  502 , and rollers  512 ,  514 ,  518  and  520  that are carried by inner shell  514 . The rollers allow the spring to move relative to the shells. One roller  512  is shown in  FIG. 13C ; the roller can move within retainers  530  and  531  that are fastened to the shell. Other mechanical means of carrying rollers or equivalent structures over which the spring can move (such as a low-friction stationary surface) are also contemplated herein. 
     Device  500  further includes mechanism  524  that allows for adjustment of the tension “T” on spring  510 . In this non-limiting example this is accomplished with nip rollers  515  and  516 ,  FIGS. 13A and 13B , through which elastomer  510  passes. The nip rollers grip the elastomer to hold it in place under normal loads expected under normal impacts that are expected. Rollers  515  and  516  are coupled such that they move in unison and in opposite directions, in this case with meshed gears  545  and  546  that are each coupled to one of the rollers. This allows one roller to be turned to tighten or loosened the spring as a means to adjust the spring preload tension. A ratchet consisting of toothed wheel  545  that is coupled to one of the nip rollers, along with pawl  546 , inhibits the elastomer from being pulled back through the nip rollers when impact on the outer shell occurs. End  551  of roller  515  is configured (e.g., with a hex nut) such that a torque wrench can be coupled to it, so that the pretension can be set as desired. This will allow the device to be calibrated to an initial preload force. 
     Pre-tensioning of the elastomer(s) helps to ensure that all shell motion occurring on impact results in stretching of the elastomer(s) (spring(s)) and absorption of impact energy. A second or more additional elastomers can be added in parallel with spring  510 . This can have a higher or lower spring constant and can be pre-tensioned as desired. The multiple springs can be selected and tensioned to achieve a desired blended energy absorption result. For example, a second elastomer could have a higher spring constant and set such that it was stretched under greater impacts, to provide more damping during higher impact events. 
     Another option, not shown in the drawings, would be to include a circuit that recorded the number of impacts to the device that exceeded the energy-absorption capacity. This could be accomplished by including a network of conductors on the outside of the inner shell and on the inside of the outer shell, arranged such that electrical contact occurred between the two networks when the shells touched (which would happen when the energy absorption members were taxed beyond their capacity). A simple circuit would be included to both measure continuity and record the data; the circuit would likely include a battery and a controller with memory. The conductors could be accomplished with thin copper strips similar to ribbon cables, or other conductors. The conductors could be arranged in a criss-cross or hatched pattern such that electrical contact was made when the shells touched even if the alignment between the shells changed due to oblique blows that twisted the outer shell, and the like.