Patent Publication Number: US-2021169168-A1

Title: Full-Flex Helmet System

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional patent Application Ser. No. 62/509,157, titled “Multi Section Full Flex Helmet System,” filed May 21, 2017. This application is also a continuation-in-part to U.S. Non-provisional patent application Ser. No. 15/985,690, titled “Full-Flex Helmet System,” filed May 21, 2018, which is not admitted to be prior art with respect to the present invention by its mention in this cross-reference section. 
     These prior applications are incorporated herein by reference in their entireties. 
    
    
     BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present invention is directed generally to a protective helmet, and more particularly to improvements to a novel helmet utilizing spring-based interconnected sections and other engineering mechanisms for dispersion of applied force and reduction of localized impact from contact events. 
     Technology in the Field of the Invention 
     Since the first plastic football helmet was introduced in 1939, helmet design has been a source of constant technological innovation with the dual goals of increasing athletic performance and reducing traumatic head injuries. Modern football helmets feature innovative designs in two primary areas: head coverings and facemasks. The plethora of available football helmet designs are driven in part by a lack of football organization restrictions. For instance, the National Football League (NFL), the most popular professional football sports league in the United States, sets mostly cosmetic standards for only chinstraps and facemasks. The following non-essential publication is incorporated by reference in its entirety to aid in the understanding of helmet design over time: Stamp, Jimmy. “Leatherhead to Radio-head: The Evolution of the Football Helmet.” Smithsonian Magazine. Smithsonian Institution. 1 Oct. 2012. Web. 14 Nov. 2019. 
     Sports-related head injuries have become a major topic of discussion over the past few years due to new research that details long-term consequences of multiple concussions, also known as mild traumatic brain injuries (mTBIs). Annually, over 40,000 hospital emergency department visits for concussion are attributable to sports participation. Youth hockey and football players are particularly susceptible to concussion. The following non-essential publications are incorporated by reference to aid in the understanding of sports-related concussions among youth: Zhao, Lan et al. “Statistical Brief #114, Sports Related Concussions, 2008 .” H - CUP: Healthcare Cost and Utilization Project . Agency for Healthcare Research and Quality. May 2011. Web. 14 Nov. 2019; Guskiewicz, K. M. et al. “Epidemiology of Concussion in Collegiate and High School Football Players.”  Am. J. Sports Med.  2000; 28:643-650. Brazarian, J. J. et al. “Mild Traumatic Brain Injury in the United States, 1998-2000 .” Brain Inj.  2005; 19(2):85-91; Halstead, M. E. et al. “Sport-Related Concussion in Children and Adolescents.”  Pediatrics.  2018; 142(6). 
     Beyond concussions, traumatic brain injury (TBI) might occur in sports settings when an external force applied to the head or body causes the recipient&#39;s brain to move relative to his or her skull. Categorically, these movements are measured in terms of linear and angular force responses. These rotational forces in multiple directions are key contributors to long-term brain injury, and repeat injury leads to chronic traumatic encephalopathy (CTE), a neurodegenerative disease. The following non-essential publication is incorporated herein by reference to aid in understanding of angular and linear biomechanics and implications for the design of types of sports helmets: Smith, T. A. et al. “Angular Head Motion With and Without Head Contact: Implications for Brain Injury.”  Sports Engineering.  2015; 18:165. 
     Football players at the NFL and college levels are being introduced to new concussion protocols driven by testing data, such as the HITS from Virginia Tech University. HITS is notable because it confirms that athletes are sustaining significant head impacts worthy of innovation in the industry—whether the sport be football, hockey, or baseball. In  Analysis of Real - time Head Accelerations in Collegiate Football Players , Duma and Manoogian conclude that the HIT system and its helmet-mounted accelerometer were able to effectively record thousands of head-impact events—and they suggested the system be integrated with existing clinical procedures to evaluate athletes on the sidelines. 
     Action is being taken at various levels of American football to reduce the frequency of concussions in order to protect players. Methods include implementation of concussion protocols at the highest levels of play, modification of practices to include fewer high-impact drills, consideration by various state legislatures of the risks and reactions to head injuries, and innovation in the helmet industry. The following non-essential publication is incorporated by reference to aid in the understanding of this national imperative: National Center for Injury Prevention and Control, “Report to Congress on Mild Traumatic Brain Injury in the United States: Steps to Prevent a Serious Public Health Problem,” Centers for Disease Control and Prevention, Atlanta, Ga., 2013. 
     Due to advances in materials science and computerized modeling as well as awareness of the high incidence of sports-related TBIs, helmet manufacturers are continually and effectively innovating upon the standard single-mold, dome-shaped sports helmet design. Newly introduced helmet designs incorporate energy-absorbing materials, geometric shell patterns, or even plate-like movable shells, and are tested extensively to quantify performance characteristics by simulating head impacts in the laboratory. The following non-essential publication is incorporated by reference to aid in the understanding of testing methods instituted by the National Operating Committee on Standards for Athletic Equipment (NOCSAE): Gwin, J. T. et al. “An Investigation of the NOCSAE Linear Impactor Test Method Based on In Vivo Measures of Head Impact Acceleration in American Football.”  J. Biomech. Eng.  2010; 132(1). 
     These approaches, while improvements in their own right, do not capture the benefits introduced by the present invention&#39;s re-conceptualization of the fundamental sports helmet design. The present invention provides a multi-sectional helmet with planar compression springs serving as connectors and constraints for the multiple sections. The present invention pertains to newly disclosed and unique designs in the present inventors&#39; helmet system, the claimed priority of which was disclosed in U.S. Non-provisional patent application Ser. No. 15/985,690, titled “Full-Flex Helmet System,” filed May 21, 2018. 
     The inventors&#39; prior disclosure, while presenting their fundamental innovations, failed to suggest certain useful designs described by the present invention. In the inventors&#39; prior disclosure, compression springs were wrapped around bolts attached to housing strips along adjacent sectional parts, wherein the bolts were further anchored immovably at one end to one sectional part and anchored movably at the other end to the adjacent sectional part, thus allowing for compression and extension of the spring and sliding of the spring along the bolt. The newly disclosed system introduces the potential for original manufacturing processes and has exhibited optimized helmet impact force dispersion, specifically by modulation of spring parameters and spring attachment to the helmet&#39;s sectional parts, as well as by enablement of spring bending radially toward the center of the helmet. 
     It is the objective of the present disclosure to enable through descriptive teaching the method of manufacture and system design of a novel multi-sectional helmet with superior impact dispersion performance to previous helmet designs. 
     BRIEF SUMMARY OF THE INVENTION 
     In one exemplary embodiment of the present invention, a multi-sectional helmet is provided with planar compression springs serving as sectional connectors and constraints between adjacent sectional parts, generating gaps between these sectional parts. In this embodiment, an off-the-shelf polycarbonate helmet has been cut into sections and re-attached by arrays of springs. In first and second preferred embodiments, respectively, the helmet is sectioned into fifths and fourths. 
     In another embodiment of the present invention, a multi-sectional helmet is assembled from sectional parts specifically designed as sectional parts. 
     In these or additional embodiments, presently-marketed helmet shell materials could be utilized. The shell could consist of a purely polycarbonate material, or could incorporate other advanced, lightweight and high-strength materials. In these or additional embodiments, gaps between sectional parts can be covered by flanged material extending from one sectional part and overlapping the adjacent sectional part to prevent exposure of the interior of the helmet to the elements. 
     The main purpose of the present invention is to reduce the impact of force sustained through construction, military, or sporting events to include operation of motorcycles, all-terrain vehicles, and other motorized vehicles. Furthermore, the present invention may be applied as a medical intervention to protect individuals prone to falling. The invention provides increased safety to the user-wearer, and is distinguishable over the present state of the art, including, but not limited to: single mold shells with internal padding, including those shells made of energy-absorbing materials; layered shells; plate-like shells where external layers that glide over internal layers; shells with arrays of spine structures; and shells with columnar springs and other compression devices. 
     Upon direct impact with an oppositely moving external force along the exterior of the present invention, the helmet directs an impact force back outwards and around the perimeter of the interconnected sections. The same impact-reducing mechanism is activated in response to a fall or body contact that angles or turns the user-wearer&#39;s head into a solid object. 
     It is an object of the present invention to improve recent advances in helmet materials and shape by means of a new system introducing enhanced performance and safety benefits from the novel design. 
     It is another object of the present invention to provide a new safety helmet for use in sporting, construction, military, motorized vehicle, and medical endeavors through original marketing and manufacture. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The unique attributes of the multi-sectional helmet are presented in detailed embodiments below. Chiefly, the apparatus described in this application is designed to optimally disperse, and thus blunt, force of impact sustained to its external shell. In doing so, the apparatus may present performance and safety benefits to its wearer over alternative helmet designs. The present invention will be better understood from the following detailed description with reference to the following drawings: 
         FIG. 1  is a top plan view of a first embodiment of the multi-sectional helmet of the present invention. 
         FIG. 2  is a bottom view of the multi-sectional helmet depicted in  FIG. 1  showing the interior of the helmet. 
         FIG. 3  is a side view of the multi-sectional helmet depicted in  FIG. 1 . 
         FIG. 4  is a front view of the multi-sectional helmet depicted in  FIG. 1 . 
         FIG. 5  is an interior view of the left front of the multi-sectional helmet depicted in  FIG. 1  from the perspective of the wearer of the helmet. 
         FIG. 6  is a top plan view of a second embodiment of the multi-sectional helmet of the present invention. 
         FIG. 7  is a bottom view of the multi-sectional helmet depicted in  FIG. 5  showing the interior of the helmet. 
         FIG. 8  is an enlarged bottom view of the interior of the multi-sectional helmet depicted in  FIG. 5  showing the point where all four sectional parts of the helmet are joined together. 
         FIG. 9  is a front view of the multi-sectional helmet depicted in  FIG. 5 . 
         FIG. 10  is a top front view of the multi-sectional helmet depicted in  FIG. 5  showing the facemask attached. 
         FIG. 11  is an interior view of the right side of the multi-sectional helmet depicted in  FIG. 5  from the perspective of the wearer of the helmet. 
         FIG. 12  is an interior view of the right side of the multi-sectional helmet depicted in  FIG. 5  from the perspective of the wearer of the helmet wherein interior padding has been inserted into the helmet. 
         FIG. 13  is an enlarged side view of an embodiment of the isolated spring used for bridging gaps between sectional parts of the multi-sectional helmet, wherein a cap is affixed to one end of the spring. 
         FIG. 14  is an enlarged schematic representation of a cross-sectional view of a closed gap between adjacent sectional parts of an embodiment of the multi-sectional helmet of the present invention. 
         FIG. 15  is an enlarged schematic representation of a cross-sectional view of an open gap between adjacent sectional parts of an embodiment of the multi-sectional helmet of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS 
     As depicted in  FIG. 1  and  FIG. 2 , in this first exemplary embodiment a helmet is segmented into five sectional parts  20 A,  20 B,  22 A,  22 B,  22 C meeting at junction  21  at the apex of the wearer&#39;s head and contoured around the side, back, and top circumference of the wearer&#39;s head. Of the sectional parts  20 A,  20 B,  22 A,  22 B,  22 C, the sectional parts  20 A,  20 B are frontal and the sectional parts  22 A,  22 B,  22 C are rear. The sectional parts may include one or more depressions or vents, for example  24 A,  24 B. 
       FIG. 2  shows the sectional parts  20 A,  20 B,  22 A,  22 B,  22 C evenly spaced away from each other by gaps  28 ,  29  by planar arrays of uniform-width springs  32  which are securely attached on the interior of the helmet at endpoints, for example  34 A,  34 B. The springs  32  use tempered high-carbon steel, also referred to as music or piano wire; these springs exhibit high tensile strength and fatigue life, are designed to withstand high load stress, and are ideal for cyclic load stresses. Alternative spring embodiments anticipated herein include springs using stainless steel, alloy steel, carbon steel (including low-, medium-, and high-carbon), and any other material suitable for manufacture of compression springs. Furthermore, alternative embodiments anticipated herein might feature non-uniformity with respect to spring width, for instance with wider springs at the base of the helmet compared to the apex. The spring array and attachment design generates gaps, for example  28 ,  29 , between pairs of adjacent sectional parts, for example  20 A,  20 B for gap  28  and  22 A,  22 B for gap  29 , which may be covered by material, for example  30  for gap  28  and  31  for gap  29 , extending from one sectional part and overlapping the adjacent sectional part within the helmet interior. Alternative embodiments anticipated herein might feature material illustrated by  30 ,  31  on the exterior of the helmet instead of the interior, serving the same protective purpose. Here, gaps  28 ,  29  generated by an array of springs anchored immovable at their ends are covered by interior material  30 ,  31  extending from sectional parts  20 B,  22 B and overlapping adjacent sectional parts  20 A,  22 A, preventing exposure of the interior of the helmet to the elements. The material  30 ,  31  could, but need not be limited to the same material makeup as the helmet shell. The material  30 ,  31  could also be adhesively bound to the helmet or manufactured as sectional flange ends. 
     As an example of springs anchored immovable at their ends between sectional parts, spring  32  is anchored by adhesive  34 A,  34 B to sectional parts  22 A,  22 B. In this embodiment, fasteners  26  ( FIG. 1 ) penetrate sectional parts  20 A,  20 B,  22 A,  22 B,  22 C radial to the wearer&#39;s head, and for spring  32  these fasteners also penetrate attachment strips  36 A,  36 B so that adhesive  34 A,  34 B anchors spring  32  to both attachment strips  36 A,  36 B and the fasteners. The adhesive, both the spring adhesive  34 A,  34 B and adhesive for attaching the material  30 ,  31 , used in this exemplary embodiment is an off-the-shelf epoxy, but in mass production might include an industrial cement, cyanoacrylate, adhesive tape, ultrasonic welding, or any other bonding agent or device demonstrated effective in the sporting, construction, military, motorized vehicle, or medical industries. 
     Referring now to  FIG. 3 , a side view of this embodiment is presented. Gap  38  between frontal sectional part  20 A and rear sectional part  22 A is formed by an array of springs anchored immovable at their ends between sectional parts  20 A,  22 A. Gap  38  is covered by material  40  extending between the adjacent sectional parts  20 A,  22 A. As an example of springs anchored immovable at their ends between sectional parts, spring  42  spaces away adjacent sectional parts  20 A,  22 A and is partially visible through ear cavity  44 A. 
     In  FIG. 4 , a front view of this embodiment is presented. Gap  28  between adjacent frontal sectional parts  20 A,  20 B is formed by an array of springs anchored immovable at their ends between sectional parts  20 A,  20 B, and gap  28  is covered by material  30  extending between the adjacent sectional parts  20 A,  20 B. Rear sectional parts  22 A,  22 B,  22 C are visible through the interior of the helmet, and ear cavities  44 A,  44 B are situated to optimize hearing for the wearer. 
     In  FIG. 5 , an interior view from the perspective of the wearer of the helmet of the left front of this embodiment depicts spring  32  bridging the gap between sectional parts  22 A, 22 B, anchored to attachment strips  36 A,  36 B at both ends by adhesive  34 A,  34 B. 
     Referring now to  FIG. 6  and  FIG. 7 , an alternative exemplary embodiment of the present invention is a helmet segmented into four sectional parts  60 ,  62 A,  62 B,  64  meeting at junction  80  at the apex of the wearer&#39;s head and contoured around the side, back, and top circumference of the wearer&#39;s head. Of the sectional parts  60 ,  62 A,  62 B,  64 , the sectional part  60  is frontal, sectional parts  62 A,  62 B are side, and sectional part  64  is rear. The frontal sectional part  60  may include one or more depressions or vents, for example  66 A,  66 B. The sectional parts  60 ,  62 A,  62 B,  64  are spaced away from each other by arrays of springs  74 , generating gaps between pairs of adjacent sectional parts which may be covered by material extending from one sectional part and overlapping the adjacent sectional part. For example, gap  68  is generated by an array of springs anchored immovable at their ends between sectional parts  60 ,  62 A, and material  70  extends from sectional part  60  and overlaps adjacent sectional part  62 A, covering gap  68  to prevent exposure of the interior of the helmet to the elements. As an example of springs anchored immovable at their ends between sectional parts, spring  74  is anchored by adhesive  78 A,  78 B to attachment strip  76  and material  70  which are affixed to sectional parts  60 ,  62 A. 
     In  FIG. 8  an enlarged bottom view of the interior of this embodiment depicts junction  80  at the apex of the wearer&#39;s head where sectional parts  60 ,  62 A,  62 B,  64  are joined together. 
     In  FIG. 9 , a front view of this embodiment is presented. Gap  98  between adjacent sectional parts  62 A,  64  is formed by an array of springs anchored immovable at their ends between sectional parts  62 A,  64 , and gap  98  is covered by material  90  extending between the adjacent sectional parts  62 A,  64 . Rear sectional part  64  is visible through the interior of the helmet, and ear cavities  72 A,  72 B are situated to optimize hearing for the wearer. 
     As depicted in  FIG. 10 , facemask  100  has been attached to this embodiment, such that impact to any one of sectional parts  60 ,  62 A,  62 B,  64  or facemask  100  causes any combination of spring compression, spring bending radially toward the center of the helmet, and movement of one or more sectional parts towards and away from one another, thereby distributing force by external impact. 
     In  FIG. 11 , the interior view of the right side of this embodiment is depicted from the perspective of the wearer of the helmet showing arrays of springs generating gaps between pairs of adjacent sectional parts  60 ,  62 A,  62 B,  64 . As an example of springs anchored immovable at their ends between sectional parts, spring  74  is anchored by adhesive  78 A,  78 B to attachment strip  76  and material  70  which are affixed to sectional parts  60 ,  62 A. In  FIG. 12  an enlarged view of this region depicts the interior of the helmet after covers  120  have been installed over springs and padding  122  has been installed throughout the helmet interior. 
     Referring now to  FIG. 13  and  FIG. 14 , an embodiment of the present invention comprises caps  132 A,  132 B affixed to either end of spring  130  for installation into the multi-sectional helmet. In  FIG. 13  an enlarged side view of spring  130  depicts attachment of cap  132 A to an end of spring  130  wherein the end of cap  132 A that fits inside spring  130  is threaded to facilitate joining of spring  130  and cap  132 A. In an alternative embodiment, the end of cap  132 A that fits inside spring  130  is smooth and fits tightly within spring  130  upon installation.  FIG. 14  depicts installation of spring  130  between sectional parts  134 A,  134 B of an embodiment of the present invention, with caps  132 A,  132 B affixed to both ends of spring  130 . Installed, these caps  132 A,  132 B facilitate the anchoring of the springs by adhesive attachment, for example  34 A,  34 B ( FIG. 2 ). In another embodiment, caps  132 A,  132 B are threaded at their ends distal to spring  130  to facilitate anchoring of the springs by screwing caps  132 A,  132 B into adjacent sectional parts using Phillips, slotted, hex, Torx, or any other screw drive. In  FIG. 14  force vector  140  depicts force from external impact applied in the direction from sectional part  134 B toward sectional part  134 A, compressing spring  130  and closing the gap between sectional parts  134 B,  134 A. Material  136  extending from sectional part  134 B overlaps sectional part  134 A both in the presence and absence of external force in order to prevent exposure of the interior of the helmet to the elements. 
     In  FIG. 15 , another embodiment of the present invention comprises fasteners  152 A,  152 B planar to the wearer&#39;s head anchored by adhesive  158 A,  158 B to sectional parts  154 A,  154 B, anchoring immovably spring  150  at both of its ends to sectional parts  154 A,  154 B. In this depiction, no force from external impact is applied, thus gap  160  spaces sectional parts  154 A,  154 B away from each other and material  156  extends from sectional part  154 B to overlap sectional part  154 A to prevent exposure of the interior of the helmet to the elements. 
     Two embodiments of the present invention, namely helmets segmented into five and four sections, were subjected to the NOCSAE Pneumatic Ram Impact tests (section 5.2). These tests were conducted under NOCSAE DOC (ND) 002-17m19 “Standard Performance Specification for Newly Manufactured Football Helmets.” After the required system checks were conducted, the Pneumatic Ram Impact tests were conducted on each embodiment, impacting the helmet at the following six locations: Side, Rear Boss NC, Rear Boss CG, Rear, Front Boss, and Random. The Random location tested for both embodiments was 7°, −135°, 42.67 mm above the basic plane, and 28.64 mm right of the rear midsagittal plane. During impact, resultant peak rotational acceleration experienced by the test headform was measured in radians per second squared (rad/s 2 ), and Severity Index (SI) values were also measured. 
     For a first embodiment comprising five sections, peak rotational accelerations for the six locations were 5011, 3992, 3378, 3320, 5436, and 2400 rad/s 2 , respectively, and SI values for the six locations were 134, 123, 199, 187, 128, and 206, respectively. For a second embodiment comprising four sections, peak rotational accelerations for the six locations were 4358, 2646, 2829, 3278, 5124, and 2742 rad/s 2 , respectively, and SI values for the six locations were 120, 92, 200, 191, 137, and 212, respectively. These data demonstrate acceptable resultant peak rotational acceleration experienced by the test headform during impact, as well as acceptable SI values. Thus, these two embodiments of the present disclosure exhibited optimized helmet impact force dispersion. 
     Throughout this specification and the claims, the term “spring parameters” includes parameters of compression springs, including outside diameter, inner diameter, mean diameter, free length, wire diameter, index, solid height, active coils, pitch, rate, and handedness. The term “adhesive” includes glue, resins, epoxies, industrial cement, adhesive tape, ultrasonic welding, non-reactive and reactive adhesives, and any other bonding agent or device. The term “radial fasteners” is used for fasteners penetrating sectional parts radial to the wearer&#39;s head, and includes screws, nails, staples, bolts, pins, and rivets. The term “planar fasteners” is used for fasteners in plane with the wearer&#39;s head, and includes screws, nails, staples, bolts, and pins. The terms “overlap” and “overlapping” include extending over, extending under, and extending both over and under to cover partly.