Patent Description:
Protective headgear and helmets have been used in a wide variety of applications and across a number of industries including sports, athletics, construction, mining, military defense, and others, to prevent damage to a user's head and brain. Damage and injury to a user can be prevented or reduced by helmets that prevent hard objects or sharp objects from directly contacting the user's head. Damage and injury to a user can also be prevented or reduced by helmets that absorb, distribute, or otherwise manage energy of an impact. <CIT> discloses a safety helmet comprising a main body, an overbody spaced from the main body to form an air space between the two, an inner body within the main body, primary air vent apertures extending upwardly and outwardly through the inner and main bodies to the air space, and secondary air vent apertures extending upwardly and outwardly through the overbody, so that both the air within the main body, and within the air space between the main and over bodies, will vent by convection when heated. <CIT> discloses a helmet of the type comprising an outer shell substantially rigid and an inner cap, made of a material suitable for absorbing eventual shocks, comprising at least two superimposed layers having different densities, a low density inner layer, in contact with the user's head, and an outer layer having an higher density, interposed between the inner layer and the outer shell.

The present application provides a helmet in accordance with the claims which follow.

Other aspects, features, and advantages will be apparent to those artisans of ordinary skill in the art from the DETAILED DESCRIPTION and DRAWINGS, and from the CLAIMS.

This disclosure, its aspects and implementations, are not limited to the specific helmet or material types, or other system component examples, or methods disclosed herein. Many additional components, manufacturing and assembly procedures known in the art consistent with helmet manufacture are contemplated for use with particular implementations from this disclosure. Accordingly, for example, although particular implementations are disclosed, such implementations and implementing components may comprise any components, models, types, materials, versions, quantities, and/or the like as is known in the art for such systems and implementing components, consistent with the intended operation.

The word "exemplary," "example," or various forms thereof are used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as "exemplary" or as an "example" is not necessarily to be construed as preferred or advantageous over other aspects or designs. Furthermore, examples are provided solely for purposes of clarity and understanding and are not meant to limit or restrict the disclosed subject matter or relevant portions of this disclosure in any manner. It is to be appreciated that a myriad of additional or alternate examples of varying scope could have been presented, but have been omitted for purposes of brevity.

While this disclosure includes a number of embodiments in many different forms, there is shown in the drawings and will herein be described in detail, particular embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principles of the disclosed methods and systems, and is not intended to limit the broad aspect of the disclosed concepts to the embodiments illustrated.

This disclosure provides a device, apparatus, system, and method for providing a protective helmet that can include an outer shell and an inner energy-absorbing layer, such as foam. The protective helmet can be a bike helmet used for mountain biking, motocross, powersports, snow sports, cycling helmets, water helmets, skateboard helmets, other sports, and in other industries using protective headwear or helmets including visors, for individuals such as construction workers, soldiers, fire fighters, and pilots. Each of the above listed sports, occupations, or activities can use a helmet that includes single or multi-impact rated protective material base that can also include comfort padding or support material on at least a portion of the inside of the helmet. More particularly, the features and improvements of the helmet described herein can benefit off-road helmets, or helmets used for off-road activities, such as motocross helmets. As appreciated by those of ordinary skill in the art, motocross helmets are formed without face shields or translucent or transparent visors to cover the faceport of the helmet and the face of the helmet wearer. However, even with the open faceport and no shield, motocross helmets have conventionally had poor ventilation, making them at times hot and uncomfortable for the helmet wearer.

<FIG>, depicts an elevational side view of a left side <NUM> of a powersports helmet <NUM> according to a non-limiting aspect of the present disclosure. The helmet <NUM> comprises a segmented outer shell or segmented shell <NUM>, an energy management, energy-absorbing, or impact material, layer, or liner <NUM> disposed within the outer shell <NUM>. The helmet <NUM> may also comprise a visor <NUM> disposed over, and providing shade to, a faceport <NUM> in the helmet. While the helmet <NUM> is shown as a full-face helmet, comprising a chin guard <NUM> that can define a lower edge of the faceport <NUM>, in some instances, the helmet <NUM> can be formed without the chin guard <NUM>. The chin guard <NUM> when present, may attach to a main body of the helmet <NUM> at the A-pillar <NUM>, where the A-pillar defines a rearmost portion of the faceport.

The energy management liner <NUM> can comprise one or more materials or layers, such as an outer energy management layer <NUM> and an inner energy management material or layer <NUM>. The outer shell <NUM> can comprise any materials known in the art of helmets, such as, but not limited to, one or more of ethylene vinyl acetate (EVA) Acrylonitrile butadiene styrene (ABS), polyvinylchloride (PVC), polycarbonate (PC), polyethylene terephthalate (PET), or other plastic, as well as, resin, fiber, fiberglass, carbon fiber, textile, Kevlar™, or other suitable material, whether cast, formed, molded, stamped, in-molded, injection molded, vacuum formed, or formed by another suitable process.

The energy management liner <NUM> can comprise one or more layers of any materials known in the art of helmets, such as, but not limited to, one or more of plastic, polymer, foam, or other suitable energy absorbing material that can flexibly deform with a hard outer shell to absorb energy and to contribute to energy management without breaking. The energy management liner <NUM> can be one or more layers of expanded polypropylene (EPP) or ethylene vinyl acetate (EVA), which can be used as an energy absorbing and energy attenuating material that is flexible and is able to withstand multiple impacts without being crushed or cracking. In other instances, expanded polypropylene (EPP) foam, expanded polystyrene (EPS), expanded polyurethane (EPTU or EPU), or expanded polyolefin (EPO) can be used or in-molded to absorb energy from an impact by being crushed or cracked.

A comfort liner or fit liner can be disposed inside the outer shell <NUM> and inside the energy management liner <NUM> while being disposed adjacent, and in contact with, the energy management liner <NUM>. The comfort liner can be made of textiles, plastic, foam, or other suitable material, such as polyester. The comfort liner can be formed of one or more pads of material that can be joined together, or formed as discrete components, that are coupled to the inside of the energy management material, the outer shell, or both. The comfort liner can be releasably or permanently coupled to the impact liner using snaps, hook and loop fasteners, adhesives, or other suitable materials or attachment devices. As such, the comfort liner can provide a cushion and improved fit for the wearer of hard shell helmet.

As can be seen in <FIG>, segmented outer shell <NUM> of helmet <NUM> defines or provides elongated segmented openings, gaps, vents, or channels <NUM> between the upper portion <NUM> and the lower portion <NUM>. Thus, rather than having a single unitary outer shell comprising a continuous unbroken surface as has been conventionally used, the segmented outer shell comprises multiple non-planar segments, such as upper portion <NUM> and lower portion <NUM>, that form elongated segmented openings <NUM>. The elongated segmented openings <NUM> can be long and continuous while extending between, along, or adjacent, edges of adjacent helmet segments. As shown in <FIG>, the elongated segmented opening <NUM> extends between, along, and is defined by, an outer or lower edge <NUM> of the upper portion <NUM> and an outer or upper edge <NUM> of the lower portion <NUM>. Various views of the edges <NUM> and <NUM> are also shown throughout the FIGs. , including in <FIG>.

As such, the elongated segmented openings <NUM> may extend all the way around, or substantially around (such as <NUM>% or more, <NUM>% or more, <NUM>% or more, or <NUM>% or more) around a circumference or perimeter of the helmet <NUM> (which may include omitting areas already open such as the faceport <NUM> when calculating a percentage of perimeter covered by the elongated segmented opening <NUM>). In some instances, a length L of the segmented openings <NUM> between the forward most portion <NUM> and the rearward most portion <NUM> of the segmented openings <NUM> will be in a range of <NUM>-<NUM> centimeters or <NUM>-<NUM> centimeters (cm) (<NUM>-<NUM> inches (in. )), <NUM>-<NUM> (<NUM>-<NUM> in. ), or greater than <NUM>, <NUM>, <NUM>, or <NUM> (<NUM> in. , <NUM> in. or <NUM> in. In a non-claimed example, the segmented opening <NUM> may be formed as a single continuous opening that begins near the faceport <NUM>, in-line or substantially in-line with the A-pillar <NUM>, such as having an end laterally offset a distance in a range of <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, or <NUM>-<NUM> from a line extending vertically from an A-pillar <NUM> or from a center of the A-pillar <NUM> on a left side of the faceport <NUM> to the A-pillar <NUM> on a right side of the A-pillar <NUM>. In other instances, the forwardmost portion <NUM> of the elongated segmented opening <NUM> may be forward of the vertical line extending form the A-pillar. In yet other instances, the segmented opening <NUM> may be positioned as described above, but not connect at a rear of the helmet, or at other portions of the helmet, having the segmented opening being divided into more than one opening, such as two, three, or any other desired number of elongated openings. According to the claimed invention, two segmented openings <NUM> are formed, the two segmented openings <NUM> being formed as left and right two segmented openings <NUM> being located on the upper sides of the helmet <NUM>, the left and right segmented openings or vents <NUM> being separated, e.g., by a piece of the outer shell at the top back of the crown portion of the helmet. As shown, the segmented opening(s) <NUM> may begin at an area above or vertically offset from a temple area <NUM> of the helmet <NUM> where the helmet <NUM> covers a temple of the user or wearer of the helmet <NUM>.

Thus, as shown in the FIGs. , the segmented openings <NUM> can be formed as a seam that can be defined by the edges of adjacent helmet segments, such as the lower edge <NUM> of upper portion <NUM> and the upper edge <NUM> of the lower portion <NUM>. In some instances, the adjacent edges of the helmet segments (such as edges <NUM>, <NUM>) can be radially offset from each other (in a radial direction from a center C of the helmet (such as at a center of the space to be occupied by a head of the user, or at a center of mass of the helmet) to an outer surface of the helmet <NUM>, such as a point on an outer surface <NUM> of the upper portion or on an outer surface <NUM> of the lower portion <NUM>), and comprise an overlap or overlap area O, overlapped (in a direction that is perpendicular or orthogonal to the radial offset r) by a distance in a range of <NUM>-<NUM> millimeters (mm), <NUM>-<NUM>, or more. In some instances, when the overlap O is zero (<NUM>), or does not overlap, there may still be no radial line of sight or direct line of sight in a radial direction r to the interior <NUM> or the helmet <NUM> from points outside of the helmet <NUM> looking towards the center of the helmet <NUM>. In yet other instances, there may be a small lateral separation (or negative overlap O) between the shell segments, such as upper portion <NUM> and lower portion <NUM>, to provide a clear line of sight into the interior <NUM> of the helmet <NUM>, so long as the segmented openings <NUM> still pass the relevant penetration tests and do not introduce undesirable structural weakness. However, by providing for at least some overlap O of the helmet segments <NUM>, <NUM>, a height H or the separation between helmet segments <NUM>, <NUM> in the radial direction r can be maintained by one or more reinforcement members or bushings <NUM> disposed between the upper portion <NUM> and the lower portion <NUM> to create the elongated segmented opening <NUM> in the outer shell <NUM>.

The elongated segmented opening <NUM> between portions of the segmented outer shell <NUM> can be larger in some places than in others, such as comprising a range of heights H that varies along the length or distance of the elongated segmented opening <NUM> along the helmet <NUM>, from a forward most portion <NUM> of the elongated segmented opening <NUM> (at a front of the helmet) to a rearward most portion <NUM> of the elongated segmented opening <NUM> (at the back of the helmet <NUM>). As shown in <FIG>, the vent can start at a front of the helmet from a height H of zero, with little or no vertical separation between the adjacent helmet segments (including <NUM>-<NUM> of vertical separation), and increase as the vent moves to the back of the helmet where the height H can increase to be in a range of <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, or more. In other instances, the height H of the elongated segmented opening <NUM> can be constant or vary little (such as <NUM>-<NUM>) along a length L of the elongated segmented opening <NUM>, where the length L extends between the forwardmost portion <NUM> and the rearward most portion <NUM> of the elongated segmented opening <NUM>. As such, the elongated segmented opening <NUM> can provide improvements with respect to conventional helmets and vent openings. More specifically, the elongated segmented opening <NUM> of helmet <NUM> can comprise an increase in size and area of venting at the outer shell <NUM>, while also providing improved coverage and less exposure (such as to a penetration test) with little or no line of sight from outside the helmet <NUM> to the interior <NUM> of the helmet <NUM> where the user's head will be.

Additionally, rather than providing vents that are merely small openings that go straight into the helmet, extending radially (in the direction r) the center C of the helmet or from the interior <NUM> to the outer shell <NUM>, the elongated segmented opening <NUM> in the outer shell <NUM>--defined by the edges <NUM>, <NUM>, of the helmet segments <NUM>, <NUM>, respectively--can connect or open into airflow passages or channels formed in, or through, the energy management material <NUM> so that air can travel freely through the helmet <NUM> and adjacent a head of the user. Additionally, the elongated segmented opening <NUM> allow or enable the helmet <NUM> to pass a penetration test, in which a spike is dropped onto or into the helmet <NUM>, as prescribed by applicable testing standards, such as those performed by Snell Memorial Foundation, Inc. to meet helmet testing standards such as M2015, EA2016, CMS2007, L-<NUM>, and other helmet penetration tests used for the particular helmet type being tested. The helmet <NUM> can pass the penetration test because little or no separation may be present (and overlap O may be present) between portions of the segmented outer shell <NUM>, such as the upper portion <NUM> and the lower portion <NUM>, that allow for improved airflow in, out, and through the helmet <NUM>. As such, the helmet <NUM> improves upon conventional designs in which small (and short) vent openings (such as with a width of <NUM> and a length of less than <NUM>-<NUM>) are exclusively used to prevent the penetration test spike from entering the helmet and causing the helmet to fail the penetration test. To the contrary, and as shown in <FIG>, the current helmet <NUM> can provide improved ventilation without providing a direct line of sight to the interior <NUM> of the helmet <NUM> or to the head of the helmet wearer so that the helmet <NUM> passes impact test and penetration test standards. The improved ventilation provided by helmet <NUM> can increase airflow to a point that the user will actually feel cool or cold on his head rather than just feeling less heat, which can be important for users. For example, users, such as motocross riders, can race in extreme heat, and are even at times at risk of heat exhaustion, which can and does at times cause death. As such, the improved ventilation of helmet <NUM> addresses a long-felt need for both energy management, and improved ventilation, both of which are achieved with helmet <NUM>.

With regards to improved energy management, forming the segmented outer shell <NUM> as a plurality of segmented shells, such as upper portion <NUM> and lower portion <NUM>, can provide a number of benefits. First, the inclusion or use of more than one shell segments allows for impacts to transfer more energy from the segmented outer shell <NUM> to the underlying energy management liner <NUM> than would otherwise occur with a conventional single or unitary un-segmented outer shell, thereby increasing the length of time of an impact and the average energy of the impact over time. To the contrary, conventional un-segmented shells tend to distribute impact energy throughout the outer shell for a smaller amount of time, preventing longer impacts and lower average energy levels in which more time is used to transfer energy from the outer shell to the energy management liner. With the segmented shell <NUM>, an increased depth of the energy management liner <NUM> absorbing energy through deformation, over time, is increased due to increased elastic deformation of the segmented outer shell <NUM>, thereby reducing the energy that is transferred to a center of a test dummy head where force of impact is measured, and by extension reducing an amount of energy transferred to a head of a user. By concentrating or absorbing more energy into the energy management layer <NUM>, at a greater depth and for a longer time, which can comprise EPS or other crushable or deformable material, , more of the energy management layer can be crushed leaving less energy to reach and possibly harm the user, all other things being equal. Additionally, size, location, and coupling of segments of the segmented outer shell <NUM> can also influence deformation of the outer shell during impact, thus influencing energy management (including location and distribution) of energy through the helmet <NUM> and to the user. Thus, the segmented design or configuration of the segmented outer shell <NUM> can improve energy management during impacts, such as in high-energy impacts.

In some instances, the segments of the segmented outer shell <NUM>, such as the upper portion <NUM> and the lower portion <NUM>, can be coupled or connected, so as to maintain the elongated segmented openings <NUM> by including a number of reinforcement members <NUM> between the adjacent shells. In some embodiments, the reinforcement members <NUM> can break or snap at a pre-determined or desirable level of energy, or under certain impact conditions, to assist in absorbing and managing impact energy. In other instances, the reinforcement members can remain unbroken to ensure stability of the outer shell.

The helmet <NUM> can further provide improved venting and cooling by using the elongated segmented openings <NUM> in the segmented shell <NUM> as exit ports or ventilation exhaust ports in the helmet <NUM>. The overlap O between the segmented shells can become a vent, comprising height H, that facilitates improved flows F for improved cooling, particularly exit flows. Airflow into the helmet can come through vents or openings other than elongated segmented opening <NUM>, such as through the faceport <NUM>, as well as through other opening formed at the front <NUM> of the helmet <NUM>, such as at, around, or above the faceport <NUM>, as well as at or near the chin guard <NUM>, through cheek pads <NUM> or at any other desirable location. Between the intake vents and the exhaust vents or elongated segmented opening <NUM>, the airflow can travel in specialized or dedicated airflow channels that extend between the intake vents and the elongated segmented opening <NUM> that can be formed, or disposed within, the helmet <NUM>, such as within the energy management liner <NUM> of the helmet <NUM>.

Additionally, a person of ordinary skill in the art will appreciate that any arrangement of elongated segmented openings <NUM> along other desirous portions of the helmet <NUM> may also be implemented to improve airflow F through the helmet <NUM>. Relatedly, the segmented multi-part outer shell <NUM> may comprise more than the upper portion <NUM> and the lower portion <NUM> of with elongated segmented opening <NUM> on either side <NUM> of the helmet <NUM>, the elongated segmented openings <NUM> extending along the lower edge <NUM> of the upper portion <NUM> and the upper edge <NUM> of the lower portion <NUM>.

<FIG> shows a perspective view of the helmet <NUM> with a upper portion <NUM> of the segmented outer shell <NUM> being shown as transparent, removed, or cut away, to reveal a portion of the energy management liner <NUM>, and more specifically the outer energy management layer <NUM>. As shown throughout the various FIGs. , the energy management liner <NUM> may comprise multiple energy management layers, such as an outer layer or outer energy management layer <NUM>, and an inner layer or inner energy management layer <NUM>. In some instances the outer energy management layer <NUM> may be formed of EPS or any other of the energy management materials <NUM> to manage energy in normal impact scenarios by being crushed or inelastic deformation, and the inner energy management layer <NUM> may be formed of EPP or or any other of the energy management materials <NUM> to manage energy in normal impact scenarios by being elastically deformed.

The outer energy management layer <NUM> comprises openings <NUM> that extend completely through the outer energy management layer <NUM>, extending form the inner surface <NUM> to the outer surface <NUM>. The openings <NUM> can be smaller or have a footprint or area that is less than the size, footprint, or area of the channels <NUM> of the inner energy management layer <NUM>. The outer surface <NUM> is formed as an uneven surface comprising raised portions standoffs or pillars <NUM>, and recessed portions, grooves, or channels <NUM>, which encourage and channel airflow F through the helmet in desired ways, such as from the interior <NUM> out through the elongated segmented openings <NUM> to increase ventilation and improve cooling for the user.

<FIG> show additional detail of the outer energy management layer <NUM> from <FIG>, but shown in isolation without, and away from, other parts of the helmet <NUM>. <FIG> shows a perspective view of the outer energy management layer <NUM> shown from below and in front of the layer <NUM>, which shows the inner surface <NUM> can be a surface that is one or more of smooth, round, or spherically shaped, and can additionally include vents, openings, voids, cutouts, or airflow passageways <NUM> that extend completely through the layer <NUM>. The openings <NUM> can be of any desirable shape, including elongatedly shaped.

<FIG> shows another perspective view of the outer energy management layer <NUM> similar to that of <FIG>, but instead is shown from below and in front of the outer energy management layer <NUM>. <FIG> shows additional detail of the uneven, or stepped outer surface <NUM> of the outer energy management layer <NUM> that can comprise stand-offs, ridges, pillars, bumps, columns, or protrusions <NUM> that can directly contact the outer shell <NUM> in some places, while not extending to touch the outer shell <NUM> in other places, allowing the airflow F to vent to the elongated segmented openings <NUM> in the outer shell <NUM>.

<FIG> show the outer energy management layer shown in <FIG> included within a full helmet, and various cut-way views of the helmet. <FIG> shows a cross-sectional side view taken along a center, sagittal, or median plane of the helmet <NUM>, with the front <NUM> of the helmet <NUM> being shown on the left of the figure and the rear <NUM> of the helmet <NUM> being shown on the right of the figure. <FIG> also shows the airflow F as a plurality of arrows representing flow paths and airflow through the helmet <NUM> that enter at the front <NUM> of the helmet, such as through front air intake vents <NUM> and through the faceport <NUM>, may travel along the interior of the helmet <NUM>, and may then pass through, or enter directly into, a plurality of airflow channels <NUM> in the inner energy management layer <NUM>, through openings <NUM>, and out the elongated segmented opening <NUM> in the outer shell <NUM>. A temperature of the air around and through the helmet <NUM> can change as the flow F interacts with the user's head and hair and pulls undesired or excess heat away from the head of the user. The portion of the flow F entering at the front <NUM> of the helmet <NUM>, shown at the left of <FIG>, can be cool air that enters and circulates through the helmet, and the flow F at the rear <NUM> of the helmet <NUM>, or at the right of the helmet <NUM> can be warmer or hotter air, as the flow F has evacuated, pulled, or transported heat away from the head of the user.

<FIG> also shows that the airflow F through the helmet <NUM> can be aided, assisted, or facilitated by the shape or structure of the energy management layer <NUM>. The inner energy management layer <NUM> can be inwardly disposed with respect to the outer energy management layer <NUM>, where, for convenience, the FIGs. show the outer energy management layer <NUM> with cross-hatching. The inner energy management layer <NUM> comprises a plurality of elongated channels <NUM>, and a series of fingers or ribs <NUM> disposed between and defined at least in part by the channels <NUM>. The channels <NUM> form a part of the paths of the flow F of air through the helmet <NUM>. Thus, the airflow F need not pass through indirect or circuitous pathways, nor does the airflow F need to pass through a simple hole or opening that extends radially from an outer surface <NUM>, <NUM> of the helmet <NUM> to the interior <NUM> of the helmet <NUM> (with a line of sight directly to the head of the user. Instead, the airflow F can pass smoothly and directly around a user's head at the interior <NUM> of the helmet <NUM> and through the energy management liner <NUM> and segmented outer shell <NUM> in smooth provide elongated flows that increase the interface between the airflow F within the helmet <NUM> and the head of the user for prolonged contact and improved heat transfer. The elongated channels <NUM> formed within the inner energy management layer <NUM> may extend from the front <NUM> to the back <NUM> of the helmet <NUM>, which differ from conventional power sport helmets, which have comprised openings of small sizes, such as lengths less than <NUM>-<NUM>, an circular openings with diameters of <NUM>-<NUM> that extend with a clear line of sight, a radial direction, from the outer surface of the helmet to the user's head. The size of the conventional powersports helmet openings has remained small to ensure performance during puncture test, which has limited airflow through the helmet.

<FIG> shows a perspective interior cut-away view of the front and interior of an embodiment of the helmet <NUM> with the chin guard <NUM> removed so that the energy management liner <NUM>, including the outer energy management layer <NUM> and the inner energy management layer <NUM> inside the segmented outer shell <NUM> are visible. As shown in <FIG>, the inner energy management layer <NUM> may comprise ribs or fingers <NUM> and elongated channels <NUM>. At least a portion of the channels <NUM> may be in contact with, or open to, the head of the helmet wearer so that the airflow F will be in increased contact with the wearer's head, facilitating increased evaporation and cooling. Positions of the front intake vents <NUM> and the elongated segmented opening <NUM> shown in the FIGs. have provided desirable results in testing, and good performance. The improved airflow F and elongated segmented opening <NUM> along the outer shell <NUM> can provide the same intake and exhaust areas (or larger or slightly larger exhaust areas than intake areas) to provide for good or optimal airflow through the helmet. Improved airflow F can also result from the inner energy management layer <NUM> being disposed within the outer energy management layer <NUM>, the channel <NUM> being formed completely through the inner energy management layer <NUM>, the channel <NUM> further being aligned, and overlapping a distance x of at least <NUM>, with the opening <NUM> in the outer energy management layer <NUM>. Improved airflow F can further pass through the elongated segmented openings <NUM>. In instances where less airflow is desired, such as in cold environments where a user wishes to retain body heat, the user can place plugs or stoppers made of rubber, plastic, or other suitable material into the intake vents <NUM>, elongated segmented opening <NUM>, or both, to limit the airflow through the airflow channels and reduce cooling and ventilation through the helmet.

<FIG> shows a perspective interior cut-away view from the rear <NUM> or behind the helmet to show a cross-sectional view of the energy management layers <NUM>, <NUM> inside the helmet <NUM>, and their interaction for facilitating the airflow F through the helmet <NUM> to the elongated segmented opening <NUM> in the outer shell <NUM>. When comfort padding is placed inside the helmet, the comfort padding can be placed along the fingers or ribs <NUM> of the inner energy management layer <NUM> so that the airflow F is not blocked or impeded by the comfort padding. Applicant have discovered that even mesh or fabrics and textiles with openings as part of the comfort padding that extends over the channels <NUM> can significantly diminish airflow and cooling.

<FIG>, similar to <FIG>, shows another perspective cut-away view from the rear <NUM> or from behind the helmet <NUM> so that the energy management liner <NUM> inside the helmet, and the pathways for the airflow F through the helmet to the elongated segmented opening <NUM> in the outer shell <NUM> are visible.

<FIG>, shows a cross-sectional side view of the entire segmented outer shell <NUM> of the helmet <NUM> comprising the upper portion <NUM> coupled to the lower portion <NUM> of the outer shell <NUM>. A reinforcement member <NUM> can be disposed between the upper portion <NUM> and the lower portion <NUM> of the shell <NUM>. In some instances, the reinforcement members <NUM> may be formed as bushings or sleeves comprising a flattened top portion <NUM> and a smaller stem portion <NUM>, together forming a mushroom type shape. The reinforcement members <NUM> may be formed as bushings with a generally circular or tubular shape and may further comprise an opening or channel <NUM>, which can also be circular, passing through an axis or a center of the reinforcement member <NUM>, including booth the top portion <NUM> and the stem portion <NUM>. The opening <NUM> can be for receiving a pin, rod, spindle, pinion, post, pillar, or stud <NUM>, to couple the reinforcement member <NUM> between segments of the segmented outer shell <NUM>, such as segments <NUM>, <NUM> of the helmet <NUM>.

In some instances, the reinforcement members <NUM> may not be formed as bushings per se, but may be formed as vertical offset members, such as with an opening <NUM> for receiving pins <NUM> or other similar structures that are coupled, or directly attached, to an inner surface <NUM> of the upper portion <NUM> of the segmented outer shell <NUM>, or an inner surface <NUM> of the lower portion <NUM> of the segmented outer shell <NUM>. In some instances, the reinforcement members <NUM> can be formed of a same material and at a same time of as the segmented outer shell <NUM>. As such, the outer shell <NUM> can, in some instances, still be formed as unitary outer shell, although with a non-uniformly planar surface, and elongated segmented openings <NUM>. In yet other instances, the reinforcement members <NUM> may be formed of a material that is different than, the material of the outer shell <NUM>, such as a softer more deformable material, including rubber, phenolic, plastic, fiberglass, or other suitable material capable to handle manufacturing tolerances, provide flexible support and a buffer for the outer shell <NUM>.

<FIG>, shows a cross-sectional view transverse or perpendicular to the cross-section view shown in <FIG>. 4B shows some of the upper portion <NUM> and some of the lower portion <NUM> of the segmented outer shell <NUM> with a reinforcement member <NUM> disposed between the upper portion <NUM> and the lower portion <NUM>. In some instances, the reinforcement members <NUM> may be formed with a mushroom shape comprising a flattened top portion <NUM> and a lower stem portion <NUM>, wherein the top portion <NUM> comprises an area or footprint larger than an area or footprint of the lower stem portion <NUM>. The central opening <NUM> may extend through the flattened portion <NUM> and the stem portion <NUM>, and be sized to receive a pin, rod, spindle, pinion, post, pillar, or stud <NUM>. The pin <NUM> may be formed of a unitary construction with either the upper portion <NUM> of the segmented outer shell <NUM> or the lower portion <NUM> of the segmented outer shell <NUM>. As such, the pin <NUM> may be integrally formed or molded as a single, unitary, or mono-formed piece and at a same time or in a same process as the formation or molding of the shell <NUM>, or a portion of the shell <NUM>, such as the upper portion <NUM> or the lower portion <NUM> of the segmented outer shell <NUM>. In other instances, the pin <NUM> may be formed separately from, and be later joined with, a portion of the helmet <NUM>, such as with either the upper portion <NUM> or the lower portion <NUM> of the segmented outer shell <NUM>, so that the pin <NUM> is not of a unitary construction or mono-formed.

<FIG>, shows a top-down perspective view of the lower portion <NUM> of the segmented outer shell <NUM> with four reinforcement members <NUM> disposed on four corresponding tabs or flanges <NUM> of the lower portion <NUM>. While four tabs <NUM> are shown, two at a front <NUM> of the helmet <NUM> and two at the rear <NUM> of the helmet, any desirable number of tabs <NUM> and corresponding reinforcement members <NUM> may be used. However, the number and location of tabs <NUM> and corresponding reinforcement members <NUM> shown have been found desirable. The tabs <NUM> may comprise openings <NUM> that can align with opening <NUM> in reinforcement members <NUM> which together can receive pin <NUM> or other suitable locking or securing member for coupling segments <NUM>, <NUM> of the segmented outer shell <NUM> to each other.

<FIG>, shows a bottom-up view of a rear piece of the lower portion <NUM> of the shell <NUM> taken along the section line 4D-4D shown in in <FIG>. <FIG> also shows two rear reinforcement members <NUM> for coupling the upper portion of the segmented outer shell <NUM> to the lower portion <NUM> of the segmented outer shell <NUM>.

<FIG>, shows a bottom view of the upper portion of the segmented outer shell <NUM> with four reinforcement members <NUM> coupled to pins <NUM>, corresponding to, and being configured to be mateably coupled with, the lower portion of the segmented lower shell <NUM> shown in in <FIG>. While both <FIG> and <FIG> have shown, for reference, the positions of the reinforcement members <NUM> with respect to the segmented outer shell <NUM>, when the upper portion <NUM> is coupled to the lower portion <NUM>, only one reinforcement member <NUM> per position may be used. However, in other instances, multiple reinforcement member <NUM> of varying shape, design, material, strength, and elasticity, may be used in conjunction with one another, such as by being stacked or interconnected.

<FIG>, shows a side elevational view of a top section of the side <NUM> of the lower portion <NUM> of the segmented lower shell <NUM>. <FIG> also shows front and rear reinforcement members <NUM> disposed on tabs <NUM>.

Claim 1:
A helmet (<NUM>) comprising:
a segmented outer shell (<NUM>) comprising an upper portion (<NUM>) and a lower portion (<NUM>), and defining right and left elongated segmented openings (<NUM>) that extend along an interface (<NUM>,<NUM>) of the upper and lower portions extending from a-pillars (<NUM>) on the right and left sides of a faceport to a rear of the helmet;
an energy management liner (<NUM>) disposed within the segmented outer shell and further comprising:
an outer energy management layer (<NUM>) comprising openings (<NUM>) formed completely through the outer energy management layer and having an uneven or stepped outer surface (<NUM>) comprising stand-offs, ridges, pillars, bumps, columns, or protrusions (<NUM>) so that the outer surface (<NUM>) directly contacts the outer shell (<NUM>) in some places while not extending to touch the segmented outer shell in other places, and
an inner energy management layer (<NUM>) disposed within the outer energy management layer (<NUM>), the inner energy management layer comprising channels (<NUM>) formed completely through the inner energy management layer (<NUM>) that are aligned, and overlap by at least <NUM> centimeter (cm), with the openings (<NUM>) in the outer energy management layer (<NUM>) and facilitate airflow through the elongated segmented openings (<NUM>).