Abstract:
A protective helmet having a layer of foam covering the hard shell of the helmet configured such that the foam absorbs shock from an impact thereby decreasing the amount of force translated to the head, neck, or spine of the wearer. A force-distributing shock absorber coupled to a helmet and facemask to protect the jaw from shock impacts.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Technical Field 
         [0002]    The invention relates generally to protective headgear. More specifically, the invention relates to a protective sports helmet with energy-absorbing padding and a facemask with force-distributing shock absorbers. 
         [0003]    2. Description of the Related Art 
         [0004]    The potential for an individual suffering a head injury while participating in a sporting activity depends upon the type of sport as well as the skill of its participants. High impact sports necessitate the use of the headwear; however, head injuries still occur despite participant skill. Headwear protection must also be capable of withstanding repeated impacts without imparting injury to the individual. 
         [0005]    Headwear designed to protect an individual&#39;s head from injury is commonly referred to as a helmet. Proper helmet construction cannot be emphasized enough when used in such sports as football. In fact, it is a requirement that high school, college, and professional football players wear a helmet during play. Typically, these helmets have included: an outer shell, generally made of an appropriate plastic material, having the requisite strength and durability characteristics to enable them to be used in the sport of football; some type of shock absorbing liner within the shell; a face guard; and a chin protector, or chin strap, that fits snugly about the chin of the wear of the helmet, in order to secure the helmet to the wearer&#39;s head, as are all known in the art. 
         [0006]    When a user&#39;s head impacts a hard object while wearing a helmet, some of the energy of the impact is absorbed and displaced by the padding as it compresses against and between the user&#39;s head and the outer casing. However, despite the mandated requirement for helmet use and construction, head injuries still occur in notable numbers. 
         [0007]    The rule makers for football have recognized the importance of the helmet and face mask combination and have imposed rules to help to reduce injuries. However, a rule in itself cannot prevent injury and/or maiming of a player. Such a rule can only invoke a yardage penalty, a fine, or at worst a suspension of a player. The injury and associated damage, however, will have still occurred to the victim player. 
         [0008]    Head trauma and head injuries are some of the most under diagnosed and misunderstood afflictions in sports. As more and more data and information comes to light regarding athletes and concussions, the closer sports and medical professionals come to finding a workable solution and possibly better prevention methods. 
         [0009]    In fact, the United States Congress has recently considered a study performed at the University of Michigan that revealed that football players who suffer head injuries have much higher rates of dementia and cognitive disabilities later in their lives. In response, the National Football League has announced that it will conduct scientific research that will give players and equipment managers more information about helmets and will help manufacturers know where they could improve equipment. 
         [0010]    Numerous helmet manufacturers have developed various helmet designs and materials of construction in an effort to reduce head injury. As mentioned above, the common element in all such helmets is that the outer skeletal shell is constructed of an impact resistant hard plastic shell which operates to protect the wearer&#39;s head and spine should the individual wearing such a helmet impact another person or another obstacle. However, known solutions do not adequately address the risk of head injury as evidenced by the staggering amount of head injuries that still occur. 
         [0011]    Additionally, during sporting events, blows are commonly directed to the chin or jaw. When a heavy blow is delivered to the chin, the force extends into the jaw joint. The forces are transmitted to major nerves at the base of the brain, to the blood supplies to the brain, as well as to the balance center located near the jaw joint. In short, this force can leave the athlete with a concussion. Scientific studies and practical experience time and again have demonstrated the effectiveness of chin and jaw protection in the prevention of concussion. 
         [0012]    Additionally, a helmet wearer&#39;s comfort is an additional concern to designers. Notably, a helmet should allow warm air to escape the helmet through vents and allow breathability. Accordingly, a helmet is needed which provides superior breathability, padding, and impact resistance for the user, while simultaneously offering more resilient external surfaces for contact with opposing objects. A player should have confidence that a head injury can be avoided through the use of such equipment. Likewise, a helmet is needed which provides superior protection to chin and jaw impact. 
       SUMMARY OF THE INVENTION 
       [0013]    The invention relates to a helmet having a layer of foam covering the hard shell of the helmet and a shock absorbent facemask. According to some embodiments, a helmet is configured such that the foam absorbs shock from an impact thereby decreasing the amount of force translated to the head, neck, or spine of the wearer. 
         [0014]    In some embodiments of the invention, more foam is placed in areas that protect against the most common impacts. In some embodiments of the invention, a flexible, durable plastic covering covers the foam. The plastic covering is preferably paintable and does not freeze during common sports conditions. In some embodiments the shell and the foam covering include ventilation holes to allow for breathability. 
         [0015]    In some embodiments of the helmet couples with the facemask of the helmet with a force-distributing shock absorber to protect the jaw from shock impacts. In some embodiments, the force-distributing shock absorber includes a snap-on coupling. In some other embodiments, the force-distributing shock absorber includes a quick-release coupling. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]      FIG. 1  illustrates an isometric view of a basic protective helmet of the prior art; 
           [0017]      FIG. 2A  illustrates a cross-sectional view of an improved helmet according to some embodiments of the invention; 
           [0018]      FIG. 2B  illustrates a front view of a helmet having a shell, a layer of foam, ventilation holes, and gaps in the foam according to some embodiments of the invention; 
           [0019]      FIG. 2C  illustrates a cross-sectional view of a helmet with a layer of shock absorbent foam with a deformable polymer outer-shell according to some embodiments of the invention; 
           [0020]      FIG. 2D  illustrates a front view of a helmet with a layer of shock absorbent foam with a deformable polymer outer-shell according to some embodiments of the invention; 
           [0021]      FIG. 3  illustrates an isometric detail of a helmet coupled with a facemask via a shock-absorbent facemask coupling mechanism according to some embodiments of the invention; 
           [0022]      FIG. 4A  is an overhead view of the shock-absorbent facemask coupling mechanism and a vertical member of the facemask via a snap-on, c-shaped clip according to some embodiments of the invention; 
           [0023]      FIG. 4B  is an overhead view of the shock-absorbent facemask coupling mechanism coupled with a vertical member of the facemask via a snap-on, c-shaped clip according to some embodiments of the invention; 
           [0024]      FIG. 5A  is an overhead view of the shock-absorbent facemask coupling mechanism and a vertical member of the facemask via a u-shaped clip and a securing strap according to some embodiments of the invention; and 
           [0025]      FIG. 5B  is an overhead view of the shock-absorbent facemask coupling mechanism coupled with a vertical member of the facemask via the u-shaped clip according to some embodiments of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0026]    The invention comprises an improved protective helmet. Helmets are configured to protect a wearer&#39;s head, face, and spine from a plurality of impact forces.  FIG. 1  illustrates an isometric view of a basic protective helmet  100  of the prior art. The helmet  100  includes a shell  101  configured to receive the head of a wearer of the helmet  100 . The helmet  100  comprises a front region  102 , a crown region  103 , a rear region  104 , two side regions  105 , a jaw protection region  106 , a chin strap  107 , and a facemask  108 . The helmet  100  of the prior art provides only a base level of protection against head impact and impact to the wearer&#39;s jaw and chin during a collision. 
         [0027]      FIG. 2A  illustrates a cross-sectional view of an improved helmet  200  according to some embodiments of the invention. The helmet  200  includes a shell  201  designed to securely receive the head of a wearer. In the presently preferred embodiments of the invention, the helmet  200  includes a layer of cushioning  299  coupled to the outer surface of a shell  201 . For the remainder of the disclosure, the cushioning  299  is referred to as foam. However, it will be readily apparent to those with ordinary skill in the art having benefit of this disclosure that other suitable materials, now known or later developed, that decrease shock forces are equally suitable as cushioning. 
         [0028]    The layer of foam  299  is configured to absorb impact forces on the wearer&#39;s head. In the presently preferred embodiments of the invention, the layer of foam  299  is permanently coupled with the shell  201  of the helmet  200 . 
         [0029]    In the presently preferred embodiments of the invention, the maximum thickness of the layer of foam falls within a range of 0.25 inches and 2.50 inches. In some embodiments the layer of foam  299  is contoured such that the layer is thinner in some areas and thicker in other areas. For example, in some embodiments of the invention, the foam  299  is thicker in areas most frequently impacted during the normal course of a sporting event. 
         [0030]    In the presently preferred embodiments of the invention, the layer of foam has a density in the range of 0.75 pounds per cubic foot to 2.00 pounds per cubic foot. In some embodiments of the invention, the layer of foam  299  utilizes a plurality of foam regions, each one of which possibly uses different foam density values. 
         [0031]    Although specific thickness and density values are specified herein, it will be readily apparent to those with ordinary skill in the art having the benefit of this disclosure that a wide variety of thicknesses and densities are feasible. 
         [0032]      FIG. 2A  shows the layer of foam  299  covering a front region  202 , a crown region  203 , and rear region  204  of the helmet  200 . In some embodiments of the invention, the layer of foam covers fewer regions or more regions. For example,  FIG. 2B  illustrates a front view of a helmet  200  having a shell  201  with a layer of foam  299  covering front region  202 , a crown region  203 , and side regions  205  of the helmet  200  according to some embodiments of the invention. 
         [0033]    Although specific examples of helmets are disclosed herein with placement of foam layers in specific regions, it will be readily apparent to those with ordinary skill in the art having the benefit of this disclosure that a helmet can include a foam layer in any region of the helmet. 
         [0034]    While protection against shock impact is the primary purpose of a helmet, the helmet should also provide comfort and breathability. Referring again to  FIG. 2B , the helmet  200  is configured with ventilation holes  275  disposed in the shell  201 . According to some embodiments of the invention, the layer of foam  299  includes gaps  285  for letting the ventilation holes  275  breathe. 
         [0035]    In some embodiments of the invention, the helmet  200  includes an outer-shell  298  covering a layer of foam  299 .  FIGS. 2C and 2D  illustrate a cross-sectional view and a front view of a helmet  200  with a layer of shock absorbent foam  299  with a deformable polymer outer-shell  298  according to some embodiments of the invention. 
         [0036]    In the presently preferred embodiments of the invention, the outer-shell  298  is a deformable polymer. The outer-shell  298  is preferably paintable such that a team logo, player number, etc. may be applied to the outer-shell  298 . The outer-shell  298  also preferably maintains deformability at low temperatures. Although specific preferences are disclosed, it will be readily apparent to those having ordinary skill in the art that the outer-shell  298  can be composed of a number of different materials and have a number of different configurations. 
         [0037]    As explained above, shocking blows to a human&#39;s chin or jaw can leave them with a concussion. Accordingly, some embodiments of the invention include a shock-absorbent facemask coupling mechanism to reduce the risk of injury to an athlete.  FIG. 3  illustrates an isometric detail of a helmet  300  coupled with a facemask  350  via a shock-absorbent facemask coupling mechanism  375 . 
         [0038]    According to  FIG. 3 , the shock-absorbent facemask coupling mechanism  375  comprises an axial member  376  containing a dampening mechanism  377  for absorbing force components parallel to the axial member  376 . For example, according to  FIG. 3 , the shock-absorbent facemask coupling mechanism  375  is configured such that forces components in the −z direction are absorbed by the dampening mechanism  377 . 
         [0039]    According to  FIG. 3 , the axial member  376  is coupled with an ear protection region  305  of the helmet  300 . In some embodiments of the invention, the shock-absorbent facemask coupling mechanism  375  is fixed to the helmet  300 . For example,  FIG. 3  shows the shock-absorbent facemask coupling mechanism  375  fixed to the helmet  300  via a bolt  380 . In some other embodiments, the shock-absorbent facemask coupling mechanism  375  is removably coupled to the helmet  300 . 
         [0040]    Likewise, in some embodiments of the invention, the shock-absorbent facemask coupling mechanism  375  is fixed to the facemask  350 , while in other embodiments the shock-absorbent facemask coupling mechanism  375  is removably coupled to the facemask.  FIG. 3  shows the shock-absorbent facemask coupling mechanism  375  coupled with a vertical member of the facemask  350  via a snap-on, c-shaped clip  360 . 
         [0041]      FIG. 4A  is an overhead view of the shock-absorbent facemask coupling mechanism  475  and a vertical member  450  of the facemask extending in an out of the page. The shock-absorbent facemask coupling mechanism  475  comprises an axial member  476  containing a dampening mechanism  477  coupled with a shaft  478 . The shaft  478  terminates with a snap-on, c-shaped clip  460 . The axial member is coupled with a flange  479  having a conduit  481  disposed therein. The snap-on, c-shaped clip  460  is preferably a resilient material that deforms to expand. Accordingly, the snap-on, c-shaped clip  460  is configured to snap onto the vertical member  450  of the facemask. 
         [0042]    Preferably the facemask extends far enough away from the wearer&#39;s chin such that the facemask does not impact the wearer&#39;s chin during full compression of the dampening mechanism  477 . 
         [0043]      FIG. 4B  is an overhead view of the shock-absorbent facemask coupling mechanism  475  coupled with a vertical member  450  of the facemask via a snap-on, c-shaped clip  460 . Additionally, according to  FIG. 4B , a bolt  480  is inserted into the conduit  481  for coupling the shock-absorbent facemask coupling mechanism  475  with the helmet. 
         [0044]    In some situations it may be desirable to provide a helmet having a shock-absorbent facemask coupling mechanism with a quick release feature such that the facemask can be opened without an application of force. For example, if a wearer experiences a neck injury while wearing the helmet, it is desirable to open the facemask and remove the helmet with as little force as possible to prevent further injury. Accordingly, some embodiments of the invention provide a shock-absorbent facemask coupling mechanism that uses a coupling that is easily removable. 
         [0045]      FIG. 5A  is an overhead view of the shock-absorbent facemask coupling mechanism  575  and a vertical member  550  of the facemask. The shock-absorbent facemask coupling mechanism  575  includes a u-shaped clip  560  and a securing strap  557  The shock-absorbent facemask coupling mechanism  575  comprises an axial member  576  containing a dampening mechanism  577  coupled with a shaft  578 . The axial member is also coupled with a flange  579  having a conduit  581  disposed therein. The u-shaped clip  560  is configured to accommodate the vertical member  550  of the facemask. The u-shaped clip  560  also comprises a strap  557  with the female end of a snap  556  disposed on a first end of the strap  557  and a rivet  558  disposed on the other end of the strap  556  for coupling with the u-shaped clip  560 . Likewise, the u-shaped clip  560  includes a male end of a snap  559 . Accordingly, the u-shaped clip  560  is configured to fit onto the vertical member  550  of the facemask with the strap  556  securing it therein. 
         [0046]      FIG. 5B  is an overhead view of the shock-absorbent facemask coupling mechanism  575  coupled with a vertical member  550  of the facemask via the u-shaped clip  560 . As shown, the female end of the snap  556  is snapped to the male end of the snap  559 , thereby securing the shock-absorbent facemask coupling mechanism  575  with the vertical member  550 . Additionally, according to  FIG. 5B , a bolt  580  is inserted into the conduit  581  to couple the shock-absorbent facemask coupling mechanism  575  with the helmet. 
         [0047]    Although the invention is described herein with reference to the preferred embodiment, one skilled in the art will readily appreciate that other applications may be substituted for those set forth herein without departing from the spirit and scope of the invention. Accordingly, the invention should only be limited by the Claims included below.