Patent Publication Number: US-2023137144-A1

Title: Pad assemblies for a protective sports helmet

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This Application is a continuation of pending U.S. patent application Ser. No. 16/853,387, filed Apr. 20, 2020, which is a continuation of U.S. Pat. No. 10,624,407, which is a continuation of U.S. Pat. No. 9,770,060, which claims the benefit of U.S. Provisional Patent Application Ser. Nos. 61/763,760, filed on Feb. 12, 2013, and 61/763,762, filed on Feb. 12, 2013, all of which are incorporated herein by referenced and made a part hereof. 
    
    
     TECHNICAL FIELD 
     The invention relates to pad and buckle assemblies for use with a protective helmet for a player engaged in a contact sport, such as football, lacrosse or hockey. A valve retainer portion of the pad assembly extends through a shell of the helmet such that bladders associated with an internal pad assembly can be inflated or deflated from the exterior of the shell. A retainer cap portion of the pad assembly is readily detachable from the helmet shell using standard tools. A buckle portion of the buckle assembly includes a protective cover wherein the buckle secures a chin protector assembly to a protective sports helmet. The protective cover engages and surrounds a peripheral edge of the buckle to form an assembly while the helmet is worn during the course of play. The cover can be removed and replaced without detaching the buckle from the chin protector. 
     BACKGROUND OF THE INVENTION 
     Helmets for contact sports, such as those used in football, hockey and lacrosse, typically include a rigid outer shell, an internal pad assembly coupled to an interior surface of the shell, a faceguard or face mask, and a chin protector or strap assembly that removably secures the helmet on the wearer&#39;s head. The internal pad assembly can include a number of pad elements which may be formed from absorbent foam, air, gel or a combination thereof. Some pad elements are positioned within an air-tight housing and provided with inflatable bladders such that air can be utilized as an inflation fluid to adjust the dimensions of one or more of the pad elements. In many instances, at least one valve is provided on the internal pad assembly to facilitate the introduction or removal of air from the bladders. Openings may be provided in the helmet shell and an extent of the valves may be inserted through the openings so the bladders can be adjusted, including while the helmet is being worn by a player. 
     Because end portions of the valves extend through the shell openings and are exposed to the outer surface of the shell, they are susceptible to impacts and wear over time. Conventional valves are firmly press fit into the shell openings to avoid accidentally dislodging the valve from the shell and/or from the internal pad assembly. In some conventional helmets, fitment of the valve within the opening in the shell also functions to secure or partially secure the internal pad assembly to the inner surface of the shell. Because conventional valves are firmly press fit into the shell openings, removing the internal pad assembly from the shell is cumbersome and time consuming, and in many instances can result in damage to the valve and/or the internal pad assembly. Removal of the internal pad assembly and incidences of valve damage increase when the helmet is worn in inclement weather conditions, including cold temperatures. 
     In addition, the chin strap assembly includes a central protective element that generally overlies or extends below the helmet wearer&#39;s chin, and opposed elongated strap portions that extend outward from the central element and that are releasably coupled to the helmet. Typically, the protective helmet is provided with helmet attachment portions and each strap portion is provided with a buckle having a buckle attachment portion that is releasably engageable with a respective helmet attachment portion. One example of such a buckle is disclosed in U.S. Pat. No. 8,056,151, the entire contents of which are hereby incorporated by reference. Often the buckle is configured to be moveable along the strap portion to adjust the sizing and fit of the chin strap assembly to accommodate the wearer&#39;s anatomical features. 
     Because the buckles are typically secured to an exterior of the helmet, the buckles are exposed and often subjected to numerous impacts when the helmet is worn during the course of play. The buckles must therefore be durable and impact resistant to ensure the chin strap remains properly secured to the helmet during impacts. To obtain the necessary strength and durability characteristics for the buckle, metal is often preferred as the primary buckle material, however, there are some drawbacks to its use. 
     Features and advantages of the invention will be apparent to those skilled in the art upon review of the following detailed description and accompanying drawings. 
     SUMMARY OF THE INVENTION 
     The disclosed subject matter relates to a pad assembly for a protective sports helmet having an opening. The pad assembly includes a pad member residing within a pad housing. The pad assembly also includes a retainer having a projection that fits within the opening of the helmet. The pad assembly further includes a cap that is detachably coupled to the retainer, the cap including a base portion that fits within the opening of the helmet and a flange portion that fits within a countersunk recess of the helmet, wherein the cap detachably receives the projection. 
     The disclosed subject matter further relates to a protective helmet for contact sports. The protective helmet includes a helmet shell having an opening in the helmet shell, the opening extending from an external surface of the helmet shell to an internal surface of the helmet shell. The protective helmet also includes a countersunk recess in the external surface of the helmet shell, the countersunk recess disposed around the opening in the helmet shell. The protective helmet further includes a pad assembly having a pad member residing within a pad housing, a retainer having a projection that is received within the opening of the helmet shell, and a cap that is detachably coupled to the retainer, the cap including a base portion that is received within the opening of the helmet shell and a flange portion that is received within the countersunk recess of the helmet shell, wherein the cap detachably receives the projection. 
     It is understood that other configurations of the subject technology will become readily apparent to those skilled in the art from the following detailed description, wherein various configurations of the subject technology are shown and described by way of illustration. As will be realized, the subject technology is capable of other and different configurations and its several details are capable of modification in various other respects, all without departing from the scope of the subject technology. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The drawing figures depict one or more implementations in accord with the present teachings, by way of example only, not by way of limitation. In the figures, like reference numerals refer to the same or similar elements. 
         FIG.  1    is a perspective view of a protective sports helmet having a pad assembly. 
         FIG.  2    is a perspective view of a pad assembly. 
         FIG.  3    is a cross-sectional side view of the pad assembly of  FIG.  2   . 
         FIG.  4    is a perspective view of a retainer cap for use with the pad assembly of  FIG.  2   . 
         FIG.  5    is a top view of the retainer cap of  FIG.  4   . 
         FIG.  6    is another perspective view of the retainer cap of  FIG.  4   . 
         FIG.  7    is a bottom view of the retainer cap of  FIG.  4   . 
         FIG.  8    is a perspective view of a valve retainer. 
         FIG.  9    is a bottom view of the valve retainer of  FIG.  8   . 
         FIG.  10    is a side view of the valve retainer of  FIG.  8   . 
         FIG.  11    is a perspective view of another valve retainer. 
         FIG.  12    is a perspective view of a protective sports helmet having a buckle assembly. 
         FIG.  13    is a bottom perspective view of a protective buckle cover and chin strap buckle. 
         FIG.  14    is a top perspective view of the protective buckle cover and chin strap buckle of  FIG.  13   . 
         FIG.  15    is a perspective view of the protective buckle cover of  FIG.  13   . 
         FIG.  16    is a top view of the protective buckle cover of  FIG.  13   . 
         FIG.  17    is an end view of the protective buckle cover of  FIG.  13   . 
         FIG.  18    is a side view of the protective buckle cover of  FIG.  13   . 
     
    
    
     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 - 3    illustrate a protective sports helmet  5  having an internal pad assembly  16  that includes a plurality of pad assemblies  15 . The inventive pad assembly  15  may be a jaw pad, a crown pad, an earflap pad and the like. For example, an internal pad assembly  16  may include one or more crown pads positioned in the top area of the protective sports helmet  5 , as well as a jaw pad and an earflap pad positioned on each side of the protective sports helmet  5 . 
       FIGS.  4 - 7    illustrate a cap  14  configured for threaded engagement with a valve retainer  10  (illustrated in  FIGS.  8 - 11   ), wherein a pad member  11 , a pad housing  12 , the valve retainer  10  and the cap  14  comprise the inventive pad assembly  15 . One or more pad members  11  are disposed within the pad housing  12  and the pad housing  12  is positioned within the interior of a helmet shell  7 . The valve retainer  10  is sealingly connected to or integrated with the pad housing  12 . The valve retainer  10  extends through an opening  9  in the helmet shell  7 , and the cap  14  is generally positioned within the opening  9  at the exterior of the protective sports helmet  5 . 
     As shown in  FIG.  3   , a valve body  18  is received by the valve retainer  10  and includes a central opening  22  that is delimited by a sealing member  19 , such as a check valve, a self-sealing material and the like. The valve body  18  is an elongated component that extends through at least a portion of the retainer  10  and allows inflation fluid, such as air and the like, to be compressed into or released from one or more bladders  13  associated with the pad assembly  15  of the helmet. The valve body  18  may include an end portion  62  that engages the second side  30  of the valve retainer  10  to axially locate the valve body  18  with respect to the valve retainer  10 , the end portion  62  being in fluid communication with the bladder  13 . In the event that the pad assembly  15  lacks an inflatable bladder  13 , then the valve body  18  is omitted. 
     As shown in  FIGS.  8 - 10   , the valve retainer  10  includes a plate-like base  26  having a first side  28  and a second side  30  opposite the first side  28 . The base  26  may be circular, oval and the like. The valve retainer  10  also includes a boss  27  disposed on or integral with the first side  28  of the base  26 , the boss  27  configured to provide a standoff with an inner surface  8  of the helmet shell  7 . For example, the boss  27  may engage with an inner surface  8  of the helmet shell  7  that is disposed around the opening  9 , helping to stabilize the position of the valve retainer  10  within the opening  9  of the helmet shell  7 . 
     The valve retainer  10  also includes a projection  42 , preferably threaded, extending generally perpendicularly away from the first side  28  and substantially centered on the base  26  and the boss  27 . The projection  42  includes external threads  46  and a substantially annular end surface  50 . The first side  28 , the end surface  50 , and the boss  27  may all be substantially parallel with one another. Alternatively, the boss  27  may extend in a convex shape from the first side  28  of the base  26 , such that the boss  27  is thicker near the projection  42  than it is near the outer edge of the boss  27 . At least a portion of the projection  42  is configured to extend through the opening  9  provided in the helmet shell  7 . Preferably the entire projection  42  is disposed within the opening  9  so that the projection  42  is protected by the helmet shell  7 . 
     A central through bore  58  of the valve retainer  10  extends through each of the threaded projection  42 , the boss  27  and the base  26 . The central through bore  58  is sized and configured to receive a valve body  18 . The valve body  18  may be press fit or otherwise secured (e.g., by adhesives) within the central through bore  58 . The base  26  of the valve retainer  10  is sealingly coupled to an exterior of a corresponding bladder  13  in the pad assembly  12  such that at least the second side  30  of the base  26  is in fluid communication with the bladder  13 . The bladder  13  may be RF welded, molded, overmolded and the like to the valve retainer  10 . For example, the material of the bladder  13  may be sealingly in contact with all of or a portion of the first side  28  of the base  26 , and not in contact with the boss  27 . When the valve retainer  10  is coupled to the pad housing  12  and the pad assembly  15  is secured to the interior of the helmet shell  7 , the boss  27  engages with the inner surface  8  of the helmet shell  7  surrounding the opening  9 , and the valve retainer  10  is substantially fixed with respect to the helmet shell  7 . 
     In an alternate embodiment as shown in  FIG.  11   , a valve retainer  10   a  includes a plate-like base  26   a  having a first side  28   a  and a second side  30   a  opposite the first side  28   a.  The base  26   a  is elongated and includes a pair of opposed distal ends  32 . A standoff  34  extends generally perpendicularly away from the first side  28   a  at each distal end  32 . End surfaces  38  of the standoffs  34  are configured for engagement with the inner surface  8  of the helmet shell  7 . 
     The valve retainer  10   a  also includes a projection  42   a,  preferably threaded, extending generally perpendicularly away from the first side  28   a  and substantially centered on the base  26   a.  The projection  42   a  includes external threads  46   a  and a substantially annular end surface  50   a.  The first side  28   a,  the end surface  50   a,  and the end surfaces  38  are all substantially parallel with one another. A distance between the end surface  50   a  and the first side  28   a  is approximately two times a distance between the end surface  38  and the first side  28   a.  Thus, the length of the projection  42   a  is approximately twice the length of the standoffs  34 . An extent of the projection  42   a  is configured to extend through the opening  9  provided in the helmet shell  7 . 
     A central through bore  58   a  of the valve retainer  10   a  extends through each of the threaded projection  42   a  and the base  26   a.  The central through bore  58   a  is sized and configured to receive the valve body  18  (not shown). The valve body  18  may be press fit or otherwise secured (e.g., by adhesives) within the central through bore  58   a.  The second side  30   a  of the valve retainer  10   a  may be sealingly coupled to an exterior of a corresponding bladder  13  in the pad assembly  15  such that the valve body  18  is in fluid communication with the bladder  13 . The valve retainer  10   a  can be RF welded to the exterior of the corresponding bladder  13 . When the valve retainer  10   a  is coupled to the pad housing  12  and the pad assembly  15  is secured to the interior of the helmet shell  7 , the valve retainer  10   a  is substantially rotationally fixed with respect to the helmet shell  7 . 
     As shown in  FIGS.  4 - 7   , the cap  14  includes a generally annular base portion  66  and a generally circular flange portion  70  coupled to one end of the base portion  66  and extending radially outward from the base portion  66 . The base portion  66  is internally threaded  76  for engagement with the external threads  46  on the projection  42 . The base portion  66  is configured to extend into the helmet shell opening  9 , which as discussed above is also occupied by the projection  42  of the retainer. In this regard, when the valve retainer  10  and cap  14  are installed in the helmet, portions of both the projection  42  of the valve retainer  10  and the base portion  66  of the cap  14  are threadedly engaged with one another while positioned in the shell opening  9  in the helmet shell  7 . 
     As shown in  FIG.  3   , the flange portion  70  is configured to be received within a countersunk recess  6  provided on the external helmet shell surface  4  that is immediately adjacent to and surrounds the shell opening  9 . In this regard the flange portion  70  rests on a shoulder defined by the differing diameters of the shell opening  9  and the countersunk recess  6 . The flange portion  70  includes a top surface  74  and a manipulation recess  78  is formed in the flange portion  70  and recessed with respect to the top surface  74 . When the cap  14  is positioned in the shell opening  9  and the countersunk recess  6 , the top surface  74  of the flange portion  70  is substantially flush with the outer surface  4  of the helmet shell  7  (see  FIG.  3   ). The manipulation recess  78  can be configured in a variety of ways for engagement with a standard manipulation device such as a screwdriver, star-bit, a coin, and the like. In the illustrated embodiment the manipulation recess  78  is generally in the shape of a cross, with one cross-member being longer than the other. The illustrated manipulation recess  78  is thus manipulatable using a flat blade or Phillips type screwdriver. 
     A through opening  82  is also provided in the flange portion  70  and, in the illustrated configuration, extends from a floor  86  of the manipulation recess  78  and through the flange portion  70 . The through opening  82  thus communicates with the interior of the base portion  66  of the cap  14 . When the cap  14  is threadedly coupled with the valve retainer  10 , the through opening  82  is substantially aligned with the central opening  22  of the valve body  18 . In the illustrated construction, the through opening  82  is generally cross shaped, which can accommodate slight axial misalignment of the through opening  82  with respect to the central opening  22 . 
     With the cap  14  threadedly coupled with the valve retainer  10 , the through opening  82  provides an access point for a standard inflation needle (not shown) to be inserted into the central opening  22  of the valve body  18 . When the inflation needle is moved beyond the check valve or self-sealing material provided in the valve body  18 , inflation fluid (e.g., air) can be introduced into or allowed to escape from the bladder  13  of the pad assembly  15  with which the valve retainer  10  is sealingly coupled. 
     The above described system of the valve retainer  10  and cap  14  facilitates the attachment, adjustment and removal of the pad assembly  15  without damaging or detaching the valve retainer  10  or valve body  18  from the pad assembly  15 . For example, to attach the pad assembly  15  to the protective sports helmet  5 , the pad assembly  15  is positioned such that the threaded projection  42  of the valve retainer  10  extends into the shell opening  9 . The base portion  66  of the cap  14  is then inserted into the shell opening  9  and threadedly engaged with the threaded projection  42 . In this regard, the base portion  66  is positioned radially outward of the projection  42  and the valve body  18 . The cap  14  can initially be finger tightened and then, as the components begin to draw snug, a tool, such as a screwdriver, can be used to fully tighten the cap  14  and the valve retainer  10 . Disassembly is the reverse operation, whereby the cap  14  is loosened and removed from the shell opening  9  and the valve retainer  10  can then be withdrawn from the internal side of the shell opening  9 . 
       FIG.  12    illustrates a protective sports helmet  105  having a buckle assembly  108  that may be used, for example, to secure a chin strap  107  to the protective sports helmet  105 . As shown in  FIGS.  13 - 18   , the buckle assembly  108  includes a protective cover  110  and buckle  114  that is inserted into or otherwise at least partially surrounded by the cover  110 . The illustrated buckle  114  is formed of metal and includes a central body portion  118  having a first strap opening  122  and a second strap opening  126  formed therein. The first strap opening  122  and second strap opening  126  further have strap securing portions  122   a,    126   a  that include a plurality of teeth that engage an extent of a chin strap to help secure the buckle  114  in a fixed location relative to the chin strap. Although not visible in  FIGS.  13  and  14   , the buckle  114  includes a generally rectangular perimeter defining an outer edge that is received by the cover  110 , as discussed below. 
     As best shown in  FIG.  13   , an attachment portion  130  is provided on the buckle  114  to fasten the buckle  114  and the chin strap attached to the buckle  114  to the protective helmet. The attachment portion  130  includes a central rivet  134  and in the illustrated configuration forms the female component of a snap assembly, although the attachment portion  130  may also form the male component of a snap assembly, or may be configured as one portion of other known attachment types. 
     Referring further to  FIGS.  15 - 18   , the cover  110  is formed of a relatively soft, flexible material and in some configurations, the buckle  114  may be removably inserted into the cover  110 . The buckle cover  110  includes a top wall  138 , a bottom wall  142 , and sidewalls  146   a,    146   b,    146   c,    146   d  extending between the top wall  138  and the bottom wall  142 . The cover  110  is generally rectangular and includes a longitudinal axis Lo and a lateral axis La. The sidewalls  146   a,    146   b  extend in the longitudinal axis Lo and are therefore longer than the sidewalls  146   c,    146   d,  which extend in the lateral direction La. 
     The top wall  138  defines a generally rectangular top opening  150 . The top opening  150  is sized and configured to receive a portion of the chin strap that extends over the central body portion  118  and between the first and second chin strap openings  122 ,  126  of the buckle  114 . The top opening  150  includes first and second laterally extending edges  152   a,    152   b . The bottom wall  142  defines a centrally located attachment opening  154  that is aligned with and that receives the attachment portion  130  of the buckle  114 . The attachment opening  154  includes a pair of diametrically opposed first arc segment edges  158  that extend generally in the lateral direction La and that have a first diameter, and a pair of diametrically opposed second arc segment edges  162  that extend generally in the longitudinal direction Lo and that have a second diameter greater than the first diameter. Laterally extending straight edge segments  166  extend between respective ends of the first arc segment edges  158  and second arc segment edges  162 . In some configurations, including configurations where the cover  110  is removably securable to the buckle  114 , the larger diameter second arc segment edges  162  facilitate insertion and removal of the attachment portion  130  with respect to the attachment opening  154 . In other configurations, the attachment opening  154  may be a substantially uniform circle. 
     The bottom wall  142  also defines a first strap opening  170  and a second strap opening  174 . The first and second strap openings  170 ,  174  are substantially rectangular and are positioned for alignment with the first and second strap openings  122 ,  126  in the buckle  114  when the buckle  114  is inserted into the cover  110 . As best seen in  FIG.  16   , the first and second strap openings  170 ,  174  have a length in the lateral direction La of the cover  110  that is substantially equal to a width (also in the lateral direction La) of the top opening  150 . The length of the strap openings  170 ,  174  and width of the top opening  150  generally are selected to correspond to the width of the chin strap to which the buckle  114  and cover  110  are to be attached. As also seen in  FIG.  16   , the edges  152   a,    152   b  of the top wall  138  are inwardly spaced with respect to the outer, laterally extending edges of the first and second strap openings  170 ,  174 . As a result, the top wall  138  includes overhanging portions  178  that extend above the first and second strap openings  170 ,  174 . 
     As shown in  FIGS.  15 - 18   , the cover  110  defines a continuous channel  182  having a substantially C-shaped cross section extending around a periphery of the cover  110 . The channel  182  is configured to receive and surround the perimeter and outer edge of the buckle  114 . The channel  182  is cooperatively defined by the top wall  138 , the bottom wall  142 , and the side walls  146   a,    146   b,    146   c,    146   d.  The channel  182  includes four channel segments  186   a,    186   b,    186   c,    186   d  with each segment associated with a respective one of the side walls  146   a,    146   b,    146   c,    146   d.  Segments  186   a  and  186   b  comprise side segments and extend in the longitudinal direction Lo. 
     As viewed from above ( FIG.  16   ), the segments  186   a,    186   b  are generally outwardly bowed such that the middle portions of the segments  186   a,    186   b  are laterally separated by a greater distance than the end portions of the segments  186   a,    186   b.  Segments  186   c  and  186   d  comprise end segments and extend in the lateral direction La. As viewed from above ( FIG.  16   ) the segments  186   c,    186   d  are substantially straight and parallel with one another. 
     As viewed from the side ( FIG.  18   ), the segments  186   a  and  186   b  are uniformly curved such that the top wall  38  has a convex profile while the bottom wall  142  has a concave profile. The uniform curvature extends into the segments  186   c,    186   d  such that, as viewed from the side ( FIG.  18   ), the segments  186   c,    186   d  are set at an angle or inclined in the longitudinal direction Lo, with the outermost portions of the segments  186   c,    186   d  being at a lower elevation than the inner portions of the segments  186   c,    186   d.    
     As viewed from the end ( FIG.  17   ), the segments  186   a,    186   b  are set at an angle or inclined in the lateral direction La such that the laterally outer portions of the segments  186   a,    186   b  are at a higher elevation than the laterally inner portions of the segments  186   a,    186   b.  As also seen in  FIG.  17   , portions of the top wall  138  that define the segments  186   a,    186   b  are also inclined such that the laterally outer edges of the top wall  138  are at a higher elevation than the laterally inner edges of the top wall  138 . 
     When the buckle  114  is inserted into cover  110  and the chin strap is extended through the buckle  114  and the cover  110 , the chin strap and the cover  110  cooperate to substantially completely cover the body portion  118  of the buckle  114 . More specifically, the outer portions of the buckle  114  are received within the channel  182 , and the central area of the body portion  118 , e.g., where the central rivet  134  is located, is covered by the chin strap. In this regard there is little, if any, exposed buckle surface present on the exterior of the helmet when the buckle  114  is attached to the helmet to secure the chin strap. The cover  110  may be easily removed and replaced by flexing the top wall  138  to withdraw the buckle  114  from the channel  182  and then extracting the attachment portion  130  from the attachment opening  154 . The cover  110  may be formed of a rubber material that can be colored to match or compliment the color of the chin strap, the face mask, and/or the helmet, thereby increasing the aesthetic appeal of the buckle assembly. 
     It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials or embodiments shown and described, as obvious modifications and equivalents will be apparent to one skilled in the art. For example, the valve retainer may be integrally formed with a liner portion of the pad assembly. Accordingly, the invention is therefore to be limited only by the scope of the appended claims. 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.