Patent Publication Number: US-7900279-B2

Title: Sports helmet with clamp for securing a chin protector

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     N/A 
     FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     N/A 
     TECHNICAL FIELD 
     The invention relates to a sports helmet with a clamp that secures a strap of a chin protector assembly against the helmet. More specifically, the invention provides a clamp with an embedded insert and a receiver that engages and secures the chin strap against an outer surface of the helmet. 
     BACKGROUND OF THE INVENTION 
     Helmets for contact sports, such as those used in football, hockey and lacrosse, typically include a chin protector that removably secures the helmet on the wearer&#39;s head. Chin protectors include a central portion, such as a protective cup, that engages the wearer&#39;s chin and at least one elongated strap member extending outward from each side of the cup. Conventional chin protectors are detachable from the helmet to allow for easy removal of the helmet, and for maintenance of the chin strap itself. Typically, a two-piece snap connector is used to connect each end of the chin strap to the helmet. The two-piece snap connector includes a male or stem portion of the snap that is affixed to and extends outward from the helmet, and a female or cap portion of the snap that is affixed via a buckle to the elongated strap member. An extent of the strap member is fed through the buckle and the cap is mounted to a central portion of the buckle. One conventional chin protector includes a pair of elongated strap members extending outward from opposed sides of the central cup, wherein each strap member bears a female portion of the snap. Each side of the helmet includes a pair of male snap portions, wherein each male snap portion mates with a female snap portion of the chin strap for securement of the helmet on the wearer&#39;s head. An example of an existing chin strap for a sports helmet is disclosed in U.S. Pat. No. 6,081,932 to Kraemer. 
     Some modern sports helmets position a first male snap or stem at a mid-height of the shell near the shell&#39;s frontal opening and a second stem along a lower edge of the shell. Thus, the helmet includes a stem at each upper end of the frontal opening and a stem along the lower shell edge of each ear flap. While such conventional chin straps provide some benefits, they nevertheless have certain limitations. For example, opposing players may strike the buckle during the course of play, where repeated striking may damage the buckle and/or disengage the buckle and cap from the stem. The present invention is provided to solve these limitations and to provide advantages and aspects not provided by conventional chin strap connectors used with sports helmets. A full discussion of the features and advantages of the present invention is deferred to the following detailed description, which proceeds with reference to the accompanying drawings. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a sports helmet having a chin protector assembly and a clamp for securing a chin strap against the helmet. The clamp features a main body with an embedded insert, a finger that is received by an aperture in the helmet, and a receiver that engages and secures the strap against an outer surface of the helmet. The chin strap removably connects the helmet to the wearer&#39;s head. The chin strap includes a central protective cup for the wearer&#39;s chin and at least one flexible strap member extending from opposed sides of the cup. 
     According to another aspect of the invention, the main body of the clamp has a substantially rectangular configuration with opposed rounded ends and a curvilinear outer wall arrangement. Further, the main body has an inner wall that is preferably curvilinear to match the curve of the outer surface of the shell which facilitates flush engagement between the clamp and the shell. The main body also includes an opening configured to receive an elongated fastener that extends through the opening and into the shell. The finger extends from the inner wall of the main body and includes a stub portion, a tip portion and a curvilinear intermediate portion. Preferably, the finger is configured such that the tip portion extends beyond the end of the main body. 
     According to another aspect of the invention, the receiver engages and secures an extent of the strap against an outer surface of the shell. The receiver is recessed from the inner wall to define a cavity that receives an extent of the strap and that is positioned between the opening and the finger. The cavity preferably has a depth that corresponds to a thickness of the strap such that the strap does not extend beyond the cavity or past the inner wall. The receiver also includes a plurality of gripping members that engage an outer surface of the strap. The insert is embedded within the main body and extends longitudinally between the opening and the finger. The insert has a first end with a projection that extends into the finger, and a second end that extends into the opening 
     In a secured position, an extent of the upper chin strap is securedly positioned between the helmet shell and the receiver. Thus, an inner surface of the strap is in contact with an outer surface of the helmet shell, and an outer surface of the strap member is in contact with the receiver wherein the gripping members engage the outer surface. In this manner, the strap member is “sandwiched” between the clamp, primarily the receiver, and the helmet shell. The fastener extends through the opening in the main body and through the helmet shell. The fastener contacts the second insert end that extends into the opening and exerts a force upon the second end. The finger is received by an aperture in the shell to couple the end of the clamp opposite the opening to the shell. Also in the secured position, the gripping members rigidly engage the strap member, namely the outer surface, to prevent it from slipping within the receiver. Thus, the engagement between the gripping members and the outer surface of the strap member maintains the desired position and tension of the chin protector assembly and prevents unintended loosening of the chin protector 
     Other features and advantages of the invention will be apparent from the following specification taken in conjunction with the following drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       To understand the present invention, it will now be described by way of example, with reference to the accompanying drawings in which: 
         FIG. 1  is a perspective view of a sports helmet of the present invention, showing a chin strap and a clamp in a secured position; 
         FIG. 2  is a perspective view of the clamp, showing an underside of the clamp; 
         FIG. 2A  is a perspective view of an alternate clamp, showing an underside of the clamp; 
         FIG. 3  is a cross-section of the helmet and clamp taken along line  3 - 3  of  FIG. 1  in the secured position; 
         FIG. 4  is a cross-section of the clamp taken along line  4 - 4  of  FIG. 2 ; and, 
         FIG. 5  is a perspective view of an insert that is embedded within the clamp. 
     
    
    
     DETAILED DESCRIPTION 
     While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated. 
       FIGS. 1-5  provide a sports helmet  10  and clamp  30  of the invention. Although shown as a football helmet, the helmet  10  may be one suitable for use in other sports requiring head protections, such as hockey or lacrosse. The helmet  10  comprises a shell  12 , a pair of ear flaps  14  depending from a crown or top portion  13  of the shell  12 , a frontal opening  16 , and an ear opening  18  in each ear flap  14 . Each ear flap  14  is configured to overlie the wearer&#39;s ear, while the frontal opening  16  provides an aperture through which the wearer looks while participating in the related sporting activity. The shell  12  is preferably fabricated from a plastic material having the requisite strength and durability characteristics to function as a sports helmet. The shell  12  also has a peripheral edge  17  that is continuous about the periphery of the shell  12 . As a result, the edge  17  defines the boundary of the frontal opening  16  and the lower boundary of the ear flaps  14 . 
     Additionally, the helmet  10  includes a face guard or mask  19  fixedly secured to the shell  12  by connectors  19   a  near the ear flap  14  and connectors  19   b  near an upper region of the frontal opening  16 . The face guard  19  includes a plurality of intersecting and elongated members that are configured to protect the wearer&#39;s face from blows during the sporting activity. The helmet  10  also includes an interior padding assembly  15 , which may be removably connected to an inner surface of the shell  12 . 
     A chin protector assembly  20  is utilized to removably connect the helmet  10  to the wearer&#39;s head. The chin protector assembly  20  includes a central portion, such as a protective cup  22  that receives the wearer&#39;s chin and at least one flexible strap member  24  extending from opposed sides of the cup  22 . Accordingly, the chin protector assembly  20  includes a first strap member  24  associated with a left ear flap  14  and a second strap member  24  associated with a right ear flap  14 . The cup  22  may include a slot  22   a  that receives a portion of the strap member  24  and an inner padding element (not shown). In the embodiment of  FIG. 1 , the chin protector assembly  20  includes two straps  24 ,  25  extending from each side of the cup  22 —a lower strap member  24  and an upper strap member  25 . Thus, the chin protector assembly  20  includes a total of four strap members  24 ,  25  that are connected to the shell  12 . To connect to the shell  12 , the lower strap member  24  utilizes a conventional two-piece snap connector, including a buckle  26  with a cap  27  that couples with a male or stem portion  28  extending from the shell  12 . 
     The upper strap member  25  is secured to the shell  12 , preferably at an upper portion of the shell  12  near the frontal opening  16 , by the clamp  30 . As shown in  FIGS. 2-5 , the clamp  30  includes a main body portion  32  with an opening  34 , a finger  36  and a receiver  38  positioned between the opening  34  and the finger  36 . As explained in greater detail below, the receiver  38  engages and secures an extent of the upper strap  25  against an outer surface of the shell  12 . In one embodiment, the main body  32  further includes an insert  40  (see  FIGS. 3-5 ) longitudinally embedded within the main body  32 , wherein the insert  40  is adapted to increase the rigidity and durability of the clamp  30 . The main body  32  has a substantially rectangular configuration with opposed rounded ends  42  and a curvilinear outer wall arrangement  44  that precludes pointed or sharp surfaces. Further, the main body  32  has an inner wall  46  that is preferably curvilinear to match the curve of the outer surface of the shell  12  which facilitates flush engagement between the clamp  30  and the shell  12 . Thus, the inner wall  46  has a radius of curvature that corresponds to the radius of curvature of the helmet shell  12  where the clamp  30  is secured against. 
     Referring to  FIGS. 1 and 3 , the opening  34  is configured to receive an elongated fastener  48  that extends through the opening  34  and into the shell  12 . Preferably, the opening  34  comprises a first passageway  50  (see  FIG. 3 ) with a first diameter and a second passageway  52  with a second diameter, wherein the first diameter exceeds the second diameter thereby forming a notch  54  between the first and second passageways  50 ,  52 . The upper portion or head  49  of the fastener  48  engages the notch  54  and resides within the first passageway  50 . In this manner, the head  49  resides either flush with or within the outer wall  44 . A locking element or nut  56 , including one with a sleeve that receives an extent of the fastener  48 , may be positioned within the shell  12  to stabilize the fastener  48  and the clamp  30 . The finger  36  extends from the inner wall  46  of the main body  32  and includes a stub portion  60 , a tip portion  62  and a curvilinear intermediate portion  64 . Preferably, the finger  36  is configured such that the tip portion  62  extends beyond the end  42  of the main body  32 . Alternatively, the finger  36  is positioned inward of the end  42  such that the tip  62  resides inward of the end  42 . 
     As mentioned above, the receiver  38  engages an extent of the upper strap  25  for securement against the shell  12 . In one embodiment, the receiver  38  is recessed from the inner wall  46  to define a cavity  66  that receives an extent of the strap  25  and that is positioned between the opening  34  and the finger  36 . Thus, the receiver  38  has a “U-shaped” configuration in profile and is in communication with the inner wall  46 . Referring to  FIG. 3 , the cavity  66  preferably has a depth that corresponds to a thickness of the strap  25  such that the strap  25  does not extend beyond the cavity  66  or past the inner wall  46 . The receiver  38  also includes a plurality of gripping members  70  that engage an outer surface of the strap  25 . The gripping members  70  can be teeth  72  that are formed from angled walls that converge, wherein the teeth  72  are oriented substantially parallel to the longitudinal axis of the main body  32 . Alternatively, the gripping members  70  are raised bumps or waves (not shown) adapted to engage the strap  25 . An alternate embodiment of the clamp  130  is shown in  FIG. 2A . There, the clamp  130  includes gripping members  170  with teeth  172  having a height that preferably terminates inward of the edge  174  between the inner wall  146  and the receiver  138 . The receiver  138  is aligned or flush with the inner wall  146  thereby precluding the recessed cavity  66  described above. As a result, the gripping members  170 , such as the teeth  172 , reside in the same plane as the inner wall  146  and do not extend past the inner wall  146 . 
     In another embodiment of the clamp (not shown), the receiver is a slot internally located within the main body, instead of being recessed from the inner wall. Preferably, the receiver is positioned between the insert and the inner wall, and is separated from the inner wall by a band of material adjacent to the inner wall. The receiver has a first interior wall and a second interior wall that are substantially parallel to the inner wall and that are spaced a distance apart to define the slot. The first interior wall and/or the second interior wall have gripping members for engagement with the strap member  25  inserted into the receiver. In this configuration, the main body may be formed from two distinct segments, for example an upper segment and a lower segment, that are joined together to form the receiver. Continuing with this example, the lower segment can include the depending finger and the upper segment can include the reinforcing insert. The fastener  48  is utilized to couple the upper and lower segments of the clamp. This coupling exerts a force on the upper segment with respect to the lower segment that facilitates the engagement between the gripping members and the strap member  25 . 
     Referring to  FIGS. 3-5 , the insert  40  is embedded within the main body  32  and extends longitudinally between the opening  34  and the finger  36 . Preferably, the insert  40  has a first end  74  with a projection  75  that extends into the finger  36  and terminates at the tip  62  of the finger  36 . Also, the insert  40  has a second end  76  that extends into the opening  34 . Preferably, the second end  76  has a curvilinear recess  78  that resides adjacent the notch  54 . A main portion  80  of the insert  40  is positioned above the gripping members  70 , while the projection  75  is positioned below the gripping members  70 . The main portion  80  includes at least one hole  82  that facilitates insertion and alignment of the insert  40  within the main body  32 . Since the insert  40  is adapted to increase the durability and integrity of the main body  32 , the insert  40  is fabricated from metal, such as S45C steel, and may be heat treated and/or plated, such as with zinc. To ensure durability, the main body  32  is fabricated from a high strength plastic, such as polycarbonate resin. 
       FIGS. 1 and 3  show the clamp  30  in a secured position P S  wherein an extent of the upper chin strap member  25  is securedly positioned between the helmet shell  12  and the receiver  38 . In the secured position P S , an inner surface  25   a  of the strap member  25  is in contact with an outer surface of the helmet shell  12 , and an outer surface  25   b  of the strap member  25  is in contact with the receiver  38  wherein the gripping members  70  engage the outer surface  25   b . In this manner, the strap member  25  is “sandwiched” between the clamp  30 , primarily the receiver  38 , and the helmet shell  12 . Because the receiver  38  is recessed from the inner wall  46  of the main body  32  to accept the strap member  25 , the strap  25  does not prevent the inner wall  42  from making contact with the shell  12 . The fastener  48  extends through the opening  34  in the secured position P S , wherein the fastener head  49  resides within the outer wall  44 . Preferably, the opening  34  has the first and second passageways  50 ,  52  wherein the fastener head  49  engages the notch  54  and remains within the second passageway  52 . Thus, the fastener head  49  does not protrude beyond the outer wall  44  of the clamp  30 . In the embodiment where the clamp  30  includes the insert  40 , the fastener  48  contacts the second end  76  that extends into the opening  34 . Furthermore, the recess  78  of the second end  76  accommodates an extent of the fastener  48  such that the fastener head  49  exerts a force upon the second end  76  against the notch  54 . 
     Also in the secured position P S , the finger  36  is received by an aperture  86  in the shell  12  to couple the end of the clamp  30  opposite the opening  34  to the shell  12 . Preferably, the tip  62  of the finger  36  is inserted into the aperture  86  and engages a lower surface of the shell  12 , and the finger stub  60  resides within the aperture  86  (see  FIG. 3 ). Although  FIG. 1  shows the finger  36  positioned above the fastener  48  and the opening  34 , the clamp  30  may be configured such that the finger  36  is below the opening  34 . In the secured position P S , the gripping members  70  rigidly engage the strap member  45 , namely the outer surface  25   b , to prevent it from slipping within the receiver  38 . Thus, the engagement between the gripping members  70 , for example the teeth  72  of  FIG. 3 , and the outer surface  25   b  of the strap member  25  maintains the desired position and tension of the chin protector assembly  20  and prevents unintended loosening of the protector assembly  20 . In an embodiment where the helmet  10  includes two clamps  30 , each clamp  30  secures a strap member  25  to the shell  12  near an upper portion of the frontal opening  16 . Described in a different manner, each clamp  30  secures the strap member  25  to the shell  12  above the ear opening  18 . In the secured position P S , the clamp  30  provides a low-profile connection point for the strap member  25  against the helmet shell  12 . 
     Unlike conventional chin guard connectors that feature two-piece snaps, the clamp  30  cannot be un-snapped to adjust and/or remove the strap member  25 . To move from the secured position P S  to an unsecured position which allows for adjustment and/or removal of the strap member  25 , the fastener  48  is loosened to create a gap between the main body  32  and the helmet  10 . This gap may result from pivotal movement of the clamp  30  about the finger  36 . Once a sufficient gap is created, the gripping members  70  disengage the strap  25  which allows the user to slide the strap  25  past the clamp  30 . Alternatively, the user can remove the fastener  48  and then disengage the finger  36  from the aperture  86  in the shell  12 . 
     In another embodiment of the clamp (not shown), the main body  32  comprises a first connector and a second connector with the receiver  38  residing between the first and second connectors. The first or second connectors removably couple the clamp to the helmet shell  12  and comprise the elongated fastener  48  extending through the opening  34 . Thus, the alternate clamp may include two fasteners  48  positioned about the receiver  38  for securement of the strap member  25  against the helmet shell  12 . 
     While the specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention, and the scope of protection is only limited by the scope of the accompanying Claims.