Patent Publication Number: US-7908678-B2

Title: Sport helmet with adjustable liner

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/753,100 filed Dec. 22, 2005, which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to protective sport helmets, and more particularly relates to protective sport helmets having interior liners that are adjustable to conform to the head of the wearer. 
     BACKGROUND INFORMATION 
     Protective helmets for use in a variety of different sporting events, as well as a variety of recreational activities, are well known. Helmets used by those engaged in certain sports, such as lacrosse, typically comprise a hard outer shell that surrounds a liner of energy-absorbing material. The hard outer shell of most protective helmets is typically comprised of a relatively rigid plastic material. The outer shell typically covers the protective liner that lies between the outer shell and the wearer&#39;s head. When manufactured, helmets are typically assembled by inserting a pre-sized protective liner within a pre-sized outer shell. Although a standard helmet can approximately accommodate most wearers, natural variation in head sizes and head dimensions can cause the same helmet to fit differently on different wearers. This is particularly true, for example, of youth wearers. As children and adolescents develop at different rates, head size and head dimensions vary widely among youths of the same age group. Accordingly, a standard helmet size may approximately accommodate some youths better than others. 
     One of the primary purposes of a helmet is to reduce the risk of injury to the wearer&#39;s head from forces directed to the head. In order to enhance the performance of a protective helmet, the helmet should conform securely to the wearer&#39;s head in all directions. When a helmet is not properly secured and can slip with respect to the wearer&#39;s head in the vertical direction, the fore and aft direction, or the side-to-side direction, an increased risk of injury can exist. 
     Many protective helmets include a chinstrap, which can be restrained around the chin of the wearer to secure the helmet against the top of the head. Although effective in conforming the helmet to the head of the wearer in the vertical direction, a chinstrap does not effectively secure a helmet to the head of the wearer in the fore and aft directions or side-to-side directions. The chinstraps commonly used to secure the helmet in proper position are often difficult to adjust, resulting in the helmet being improperly positioned, thus providing limited protection to the wearer. 
     Accordingly, a need remains for a protective sport helmet that can be adjusted to conform to the head size and head dimensions of the wearer in the fore and aft direction and the side-to-side direction, as well as in the vertical direction. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a protective sport helmet having an interior liner capable of conforming to the head of the wearer in the fore and aft direction and/or the side-to-side direction. The sport helmet can comprise a protective outer shell and an inner energy-absorbing liner. The liner can comprise a top portion and an anterior portion flexibly connected therebetween to adjust the fit of the helmet to the head of a wearer in the fore and aft direction. The liner can comprise a side liner portion and the outer shell can comprise a slider mechanism for engaging the side liner portion to adjust the fit of the helmet to the head of the wearer in the side-to-side direction. The liner can comprise a plurality of grooves to transfer energy across the liner material. 
     An aspect of the present invention is to provide a protective sport helmet comprising a protective outer shell and a liner insert disposed within the protective outer shell. The liner insert has a top liner portion and at least one adjustable liner portion flexibly connected to the top portion and movable from an expanded position adjacent to an inner surface of the protective outer shell to a contracted position away from the inner surface of the protective shell. 
     Another aspect of the present invention is to provide a protective sport helmet comprising a protective outer shell and a liner insert disposed within the protective outer shell. The liner insert has a top liner portion and an anterior liner portion flexibly connected to the top portion and movable from a first position adjacent to an inner surface of the protective outer shell to a second position away from the inner surface of the protective shell. 
     A further aspect of the present invention is to provide a protective sport helmet comprising a protective outer shell, at least one slide member slidably mounted on a side of the protective outer shell, and a liner insert disposed within the protective outer shell. The liner insert includes at least one side liner portion having a surface contacting the sliding member, wherein movement of the at least one slide member causes movement of the at least one side liner portion toward or away from an inner surface of the protective outer shell. 
     Another aspect of the present invention is to provide a protective sport helmet, comprising a protective outer shell and a liner insert disposed within the protective outer shell, the liner insert comprising a plurality of grooves extending longitudinally along substantially the entire length of the liner insert between the liner insert and the protective outer shell. 
     These and other aspects of the present invention will be more fully understood following a review of this specification and drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an isometric view of a protective helmet with an adjustable liner in accordance with an embodiment of the present invention. 
         FIG. 2  is a side view of the protective helmet of  FIG. 1 . 
         FIG. 3  is a front view of the protective helmet of  FIG. 1 . 
         FIG. 4  is a rear view of the protective helmet of  FIG. 1 . 
         FIG. 5  is an isometric view of a protective helmet liner with the outer shell removed in accordance with an embodiment of the present invention. 
         FIG. 6  is a rear view of the protective helmet liner of  FIG. 5 . 
         FIG. 7  is a rear side view of a protective helmet including an adjustable anterior liner portion positioned against the outer shell of the helmet in accordance with an embodiment of the present invention. 
         FIG. 8  is a side view of a portion of the helmet of  FIG. 7 . 
         FIG. 9  is a rear side view of a protective helmet including an adjustable anterior liner portion moved inwardly away from the outer shell of the helmet in accordance with an embodiment of the invention. 
         FIG. 10  is a side view of a portion of the protective helmet of  FIG. 9 . 
         FIG. 11  is a sectional view through a side portion of a protective helmet showing an adjustable side portion of a liner and a slider mounted on an outer shell of the helmet for moving the side portion of the liner inwardly and outwardly in accordance with an embodiment of the present invention. 
         FIG. 12  is a side view of the protective helmet of  FIG. 11  showing the slider in an upward position in which the side portion of the liner is in a wide position against the outer shell. 
         FIG. 13  is a front sectional view of a portion of the protective helmet of  FIG. 12  showing the slider and side portion of the liner in the wide position. 
         FIG. 14  is a frontal view of a portion of the protective helmet of  FIGS. 12 and 13  showing the side portion of the liner against the outer shell. 
         FIG. 15  is a side view of the protective helmet of  FIG. 11  showing the slider in a downward position in which the side portion of the liner is moved to a narrow position away from the outer shell. 
         FIG. 16  is a frontal view of a portion of the protective helmet of  FIG. 15  showing the side portion of the liner moved inwardly away from the outer shell. 
         FIG. 17  is a rear side view of a portion of a protective helmet including a rear slider in an unengaged position in accordance with an embodiment of the present invention. 
         FIG. 18  is a rear side view of the portion of the protective helmet shown in  FIG. 17  showing the rear slider moved to an engaged position. 
         FIG. 19  is a top view of a protective helmet liner including longitudinally extending sections having liner grooves therein in accordance with an embodiment of the present invention. 
         FIG. 20  is a front view of a protective helmet liner from the helmet of  FIG. 19  including longitudinally extending grooves in accordance with an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     The present invention is directed to protective sports helmets, such as the protective sport helmet  30  shown in  FIGS. 1-4 . As used herein, the term “sport helmet” refers to protective helmets used in various types of sporting and recreational activities. For example, the protective sport helmet may be a lacrosse helmet, field hockey helmet, football helmet, hockey helmet or the like. While a protective lacrosse helmet  30  is shown in the figures and primarily described herein, it is understood that other types of sports helmets are within the scope of the present invention. 
     The protective helmet  30  shown in the embodiment of  FIGS. 1-16  comprises a protective outer shell  32 , an inner energy-absorbing liner  34  disposed within the protective outer shell, and a face grill  36  fastened to the outer shell  32 . The protective outer shell  32  may be made of known types of relatively rigid plastic material, and is typically provided as unitary piece of material. The energy-absorbing liner  34  can comprise any conventionally known helmet liner material, such as resilient polymeric foam materials or any structure used to absorb impact such honeycombed plastic material or an air bladder. 
     As shown in  FIGS. 5 and 6 , the liner  34  of the helmet  30  comprises a plurality of liner sections. In one embodiment, the liner  34  comprises an anterior liner portion  38  and a top liner portion  40  which are flexibly attached to each other. Top liner portion  40  can comprise any suitable shape and dimensions such that it substantially surrounds the upper portion of the skull of a wearer, including the parietal region of the head. Anterior liner portion  38  can also comprise any suitable shape and dimensions such that it is disposed at least partially about the back of the skull, such as at least partially disposed about the occipital and temporal regions of the head. 
     The top liner portion  40  and the anterior liner portion  38  are flexibly connected. Such flexible attachment may be provided by a pivoting connection between separate pieces  38  and  40  as shown in the figures. Alternately, the flexible attachment may be provided by the use of flexible material between the base  38  and top  40  liner portions, e.g., a unitary liner with sufficient flex between the base and top portions. Thus, the top liner portion  40  and the anterior liner portion  38  can be joined by an engagement mechanism or can comprise a unitary piece or portions that are shaped to flexibly engage one another. As shown in the embodiment of  FIGS. 5 and 6 , the top liner portion  40  can comprise a contoured dovetail portion  42  and the anterior liner portion  38  can comprise a contoured dovetail portion  44  that flexibly mates with the contoured dovetail portion  42  of the top liner portion to allow the anterior liner portion  38  to pivot with respect to the top liner portion  40 . 
     Once the helmet  30  is placed on the head of a wearer, the fit of the helmet  30  can be tightened or loosened by adjusting the fore and aft position of the anterior liner  38 . The anterior liner portion  38  can pivot in a substantially perpendicular orientation to the plane of the top liner portion  40  to accommodate the shape of the head of the wearer. In one embodiment, the anterior liner portion  38  can pivot with respect to the top liner portion  40  from about 1 to about 20 degrees, for example, from about 5 to about 10 degrees. This configuration allows a single size helmet liner  34  and protective outer shell  32  to accommodate many head sizes and shapes by providing a customized fit in the fore and aft direction. 
     As shown in  FIGS. 4-10 , a securing mechanism  46 , such as a securing strap, can be disposed within the protective outer shell  32  and positioned to engage the anterior liner portion  38  to secure the anterior liner portion  38  at a desired location around the head of a wearer. As shown in  FIGS. 7 and 8 , the anterior liner portion  38  can be positioned outward against an interior surface of the protective outer shell  32  in the unengaged position. As shown in  FIGS. 9 and 10 , the anterior liner portion  38  can be secured against the head of a wearer and drawn within the protective outer shell  32  in the engaged position. 
     As shown in  FIG. 7 , in the unengaged position, the securing mechanism  46  can comprise a strap  48  having one of hook and loop closure means and a tab  50  of the other of hook and loop closing means for securably mating therewith. In one embodiment, the tab  50  can be disposed on the anterior liner portion  38  and the strap  48  can be disposed through a slot  52  within the outer shell  32 . As shown in  FIGS. 9 and 10 , in the engaged position, the strap  48  can be secured to the tab  50  and the anterior liner portion  38  can be secured against the head of a wearer. 
     It can also be desirable to adjustably secure a protective helmet against the head of a wearer in the lateral or side-to-side direction. As shown in  FIGS. 11-16 , the liner of the present invention can also comprise at least one side liner portion  60  adjustably securing the helmet  30  to the head of a wearer. Such adjustable side liner portions  60  are typically provided on both sides of the helmet  30 , and are movable outwardly and inwardly with respect to the outer shell  32  in order to effectively widen and narrow the fit of the helmet  30 . The side liner portion  60  can comprise a relatively smooth interior surface  62  for contacting the side of the face of a wearer, and a contoured exterior surface  64  comprising a plurality of ramped recesses  66  facing the inner surface of the outer shell  32 . A slider  68  slidably mounted on the outer shell  32  of the helmet  30  comprises an interior side having a plurality of angled ramps or steps  70  and an exterior side having a manually engageable surface  72 . When the slider  68  is in the unengaged or wide position, the steps  70  of the slider  68  align with the contours of the recesses  66  of the side liner portion  60  as shown in  FIGS. 12-14  to provide a relatively wide fit. The unengaged wide position of the inner portion  60  is shown in  FIGS. 13 and 14 . When the slider  68  is moved by operating the manually engageable surface  72  from the unengaged wide position to the engaged narrow position, shown in  FIGS. 15 and 16 , the steps  70  of the slider  68  align against the contours of the recesses  66  of the side liner portion  60  to move the side liner portion  60  inwardly away from the outer shell in order to provide a relatively narrow fit. 
     As shown in  FIGS. 12 and 15 , the manually engageable surface  72  of slider  68  can be moved from a first position, shown in  FIG. 12 , to a second position, shown in  FIG. 15 , to effectuate the transition of the side liner portion  60  from the unengaged wide position to the engaged narrow position, and any intermediate positions therebetween. The width of the inner surface of the side liner portion  60  with respect to the outer shell  32  may be increased from the unengaged width W 1  shown in  FIGS. 13 and 14  to the engaged width W 2  shown in  FIG. 16 . In one embodiment, W 2  can be from about 0.05 to about 0.5 inches greater than W 1 . By increasing the width of the slider  68  and side liner portion  60  combination, the side-to-side fit of the liner can be adjusted to accommodate to the head of a wearer. It is contemplated herein, that a first slider can engage a first side liner portion  60  on the left side of the wearer&#39;s head and that a second slider can engage a second side liner portion  60  on the right side of the wearer&#39;s head. 
     As shown in the embodiment of  FIGS. 17 and 18 , a similar slider mechanism  80  can be used to adjust the fit of the anterior liner portion  38  discussed with respect to  FIGS. 11-16 . In this embodiment, the anterior liner portion  38  can comprise a relatively smooth interior surface for contacting the back of the head of the wearer, and a contoured exterior surface comprising a plurality of recesses. A slider  80  slidably mounted on a rear side portion of the outer shell  32  of the helmet  30  can comprise an interior side having a plurality of angled ramps or steps and an exterior side having a manually engageable surface. When the slider  80  is in the unengaged or wide position shown in  FIG. 17 , the steps of the slider  80  align with the contours of the recesses of the anterior liner portion. When the slider is moved from the unengaged position to the engaged position shown in  FIG. 18 , the steps of the slider  80  can align against the contours of the recesses of the anterior liner portion to move the anterior liner portion  38  inwardly away from the outer shell. The width of the slider  80  and anterior liner portion in the engaged position can be from about 0.25 to about 2 times the width of the slider  80  and anterior liner portion combination in the unengaged position. 
     In another embodiment, as shown in  FIGS. 19 and 20 , the top liner portion  40  can comprise a plurality of grooves  90  extending along a direction of the liner to dissipate at least some energy across the liner material upon impact. In one embodiment, the grooves  90  extend substantially along the entire length of the top liner portion  40  in the longitudinal direction. In another embodiment from about 2 to about 10 grooves can be disposed within the top liner portion  40  of the present invention. In another embodiment, the grooves can extend into the top liner portion  40  from about 2 mm to about 1.5 cm. In another embodiment, the grooves  90  can be substantially unfilled. In yet another embodiment, the grooves  90  can comprise a second foam material. The second foam material may have a different density and/or degree of compressibility. 
     Whereas particular embodiments of this invention have been described above for purposes of illustration, it will be evident to those skilled in the art that numerous variations of the details of the present invention may be made without departing from the invention.