SOFT SAFE HELMET

[0001] This application claims the benefit of U.S. Provisional Application No. 61/673,481, filed on Jul. 19, 2012. The entire disclosure of the above application is incorporated herein by reference.

[0002] The present technology relates to various protective headgear and helmets and, more particularly, to helmets for playing the game of football.

[0003] This section provides background information related to the present disclosure which is not necessarily prior art.

[0004] Various activities, such as contact sports, and in particular the sport Of American football, known generally in the Unites States simply as “football,” require the use of helmets to attempt to protect participants from injury to their heads due to impact forces that may be sustained during such activities. Various types of helmets have been in use in the sport of football, ever since participants began wearing helmets in an attempt to protect their heads. 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's head.

[0005] An existing helmet design seen on players of most football teams includes a hard shell plastic helmet. This design is intended primarily to protect the wearer's head from impact. The impact is cushioned by a shock absorbing liner of foam plastic padding surrounding the head. Elaborate testing of the impact force that the helmet can sustain before failure of the hard shell is used to evaluate the design.

[0006] There are several problems with this design. First, the wearer of the helmet is somewhat protected from impact by the spreading of the impact force to the head by the foam padding to a larger area of head, thus limiting impact damage, such as a concussion. However, the impact force is still absorbed by the head itself and transferred from the wearer's skull to the brain. Second, a further problem is the effect of the wearer's helmet impacting an opposing player. The hard shell design acts as a “battering ram” against any part of the opposing player's body. This has caused various injuries to the wearer as well as the opposing player, such as a concussion, broken bones, and even spinal injury. Third, another problem is that there is no protection from an impact causing the wearer's head to rotate far enough on the spinal column to cause injury to the spine; which in extreme cases can result in paralysis. The range of motion to avoid cervical spine injury has been determined by several medical organizations. No protection against spinal injury due to motion of the head beyond these limits is offered by existing helmet designs.

[0007] It should be noted that while it is the desire and goal that a football helmet, and other types of protective helmets, prevent injuries from occurring, the helmet of the present technology, as well as prior art helmets, due to the nature of the sport of football in particular, no protective equipment or helmet can completely and totally prevent injuries to those individuals playing the sport of football. Furthermore, no protective equipment can completely prevent injuries to a player, if the football player uses his football helmet in an improper manner, such as to butt, ram, or spear an opposing player, in violation of the rules of football. Improper use of a helmet to butt, ram, or spear an opposing player can result in severe head and/or neck injuries, paralysis, or death to the football player, as well as possible injury to the football player's opponent. No football helmet, or protective helmet, such as that of the present technology, can completely prevent head, chin, or neck injuries a football player might receive while participating in the sport of football. The helmet of the present technology is believed to offer protection to football players, but it is believed that no helmet can, or will ever, totally and completely prevent head injuries or other various types of injuries to football players.

[0008] The present technology provides an improved helmet that addresses shortcomings of existing helmets.

[0009] The present technology includes systems, processes, and articles of manufacture that relate to protective headgear, including a football helmet.

[0010] A helmet for protecting a wearer's head is provided. The helmet includes a shell configured to receive the wearer's head, At least one pad is coupled to an interior of the shell and is configured to be positioned between the wearer's head and the shell. One or more pads can be comprised by fluid filled bladders that can be interconnected to allow fluid transfer therebetween. A lower portion is coupled to the shell, where the lower portion is configured to limit flexion, extension, and lateral bending of the wearer's head. In this way, the helmet may improve player protection from an impact to the head of the wearer and may further protect opposing players. When the shell uses an elastomeric material, such as rubber or a thermoplastic elastomer, the shell may distribute the impact force to a larger area and may lessen the chance of the wearer or an opposing player suffering a concussion. The lower portion can be formed of a material that has a greater Young's modulus than the shell. The lower portion, for example, can take the form of a rigid collar that limits head motion to mitigate cervical spinal injury to the wearer. The lower portion can also include at least one tether coupled to the chest of the wearer, the back of the wearer, the left shoulder of the wearer, and/or the right shoulder of the wearer, where the tether limits a range of motion of the wearer's head.

[0011] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

[0018] The following description of technology is merely exemplary in nature of the subject matter, manufacture and use of one or more inventions, and is not intended to limit the scope, application, or uses of any specific invention claimed in this application or in such other applications as may be filed claiming priority to this application, or patents issuing therefrom. Regarding the methods disclosed, the order of the steps presented is exemplary in nature, and thus, the order of the steps can be different in various embodiments. Except in the examples, or where otherwise expressly indicated, all numerical quantities in this description indicating numerical values, degrees in a range of motion, or distances are to be understood as modified by the word “about” in describing the broadest scope of the technology.

[0019] A helmet for protecting a wearer's head is provided that includes a shell, at least one pad, and a lower portion. The shell is configured to receive the head of the wearer of the helmet. The one or more pads are coupled to an interior of the shell and are configured to be positioned between the wearer's head and the shell. The lower portion is coupled to the shell and is configured to limit flexion, extension, and lateral bending of the head of the wearer. A chin strap can be included to facilitate securing the helmet to the wearer's head.

[0020] The shell receives the wearer's head and can include a front region covering a front portion of the head, a back region covering a back portion of the head, a left region covering a left portion of the head, a right region covering a right portion of the head, and a top region covering a top portion of the head. Various ventilation holes, slots, or other apertures can be provided at various positions on the shell, including apertures located on the sides, or left and right portions, at or near the wearer's ears to facilitate hearing.

[0021] The shell can be made of various materials, including various plastic, rubber, or composite materials. In some embodiments, the shell includes an elastomeric material. An elastomeric material is one that can elastically deform in response to an applied force or stress and return to its original shape when the applied force or stress is removed. The elastomeric material is more flexible than materials typically used in football helmet shells, such as polycarbonate. The elastomeric material can therefore have a Young's modulus that is less than the Young's modulus of polycarbonate. The Young' modulus of polycarbonate can be from 2.0 up to 2.4 gigapascal (GPa). Depending on the elastomeric material used in the shell, the Young's modulus can be less than 2 GPa, and in various embodiments can be less than 1 GPa, less than 0.5 GPa, or less than 0.1 GPa.

[0022] In certain embodiments, the elastomeric material is a rubber, an unsaturated rubber, a saturated rubber, a thermoset polymer, a thermoplastic polymer, or combinations thereof. Examples of rubber include natural and synthetic rubbers, including unsaturated rubbers and saturated rubbers. Saturated rubbers include those that can be cross-linked or cured by vulcanization, such as polyisoprene, polybutadiene, styrene-butadiene, nitrile rubber, and the like. Unsaturated rubbers include those that cannot be cross-linked by vulcanization, such as ethylene propylene rubber, ethylene propylene diene rubber, silicone rubber, polyether block amides, ethylene vinyl acetate, and the like. Thermoset polymers include polyurethanes and thermoplastic polymers include polyethylene, polypropylene, polyolefin blends, styrenic block copolymers, thermoplastic copolyester, and thermoplastic polyamides, As examples, the following elastomeric materials can be formulated to have the following Young's modulus values: rubber (0.01 to 0.1 GPa); styrene-butadiene rubber (0.002 to 0.01 GPa); nitrile rubber (0.002 to 0.005 GPa); ethylene propylene diene rubber composites (0.025 to 0.050 GPa); polyurethane elastomer (0.025 GPa); polyethylene (0.11 to 0.45 GPa); polypropylene (1.5 to 2 GPa); thermoplastic copolyester (0.001 to 0.005 GPa). In addition, one can made composites and blends of materials to tailor the Young's modulus of the elastomeric material to be less than 2 GPa, including increments from 2 GPa down to 0,002 GPa.

[0023] The protective helmet includes one or more pads that can be independently formed of various materials. In some embodiments, the pad includes at least one fluid filled bladder. The fluid can be a liquid, gel, or a gas. When the fluid filled bladder is filled with a gas, the gas can be air, nitrogen, or other gases or mixtures of gases. The fluid filled bladder can include a valve for transferring fluid to and from the bladder. For example, the fit of the helmet may be tailored to the head of a particular wearer by adjusting the amount of fluid in one or more bladders positioned between the head of the wearer and the shell. Tight portions of the protective helmet can be alleviated by withdrawing fluid in a bladder at the tight location and loose fitting portions can be made snug by filling a bladder with additional fluid in the loose location. A plurality of fluid filled bladders coupled to the interior of the shell and configured to be positioned between the head and the shell can therefore be used to ensure a secure fit of the helmet on the wearer's head and reduce movement or shifting of the helmet with respect to the wearer's head.

[0024] Where a plurality of fluid filled bladders are employed, one bladder can be fluidly coupled to another bladder to allow movement of fluid between the bladders. For example, a valve can fluidly couple one bladder to another bladder and can regulate the rate of fluid transfer between the one bladder and the another bladder. Bladders around, throughout, and on opposite sides of the protective helmet can be coupled in this manner. Accordingly, should a wearer receive a force on the front of the helmet, the compression of the fluid within a bladder located at a front region of the helmet can cause the fluid to move to a bladder at a side(s) region and/or onto another bladder at a rear region of the helmet. Energy is therefore dissipated, a snug fit is retained, and the wearer's head does not bounce back and forth within the helmet.

[0025] The protective helmet also includes a lower portion coupled to the shell. The lower portion can comprise a material that is harder and less flexible than the shell. For example, the shell can be configured to receive an impact and force applied to the wearer's head that results in deforming and bending of the shell to absorb the impact energy, whereas the lower portion acts as a rigid downwardly projecting flange or collar that limits the range of motion of the wearer's head with respect to the wearer's upper torso, including chest, back, and shoulders. The lower portion can therefore provide a more defined or abrupt limit to a range of motion, where the lower portion does not flex or bend beyond the range of motion limit. In certain embodiments, the lower portion comprises a material having a Young's modulus that is greater than a Young's modulus of the shell material. For example, the lower portion can be formed of polycarbonate or other like materials. Alternatively, the lower portion can include an elastomeric material, but the elastomeric material of the lower portion would be selected to have a higher Young's modulus than the shell. In this way, the lower portion is more rigid and less flexible than the shell.

[0026] As described, the lower portion of the protective helmet is configured to limit flexion, extension, and lateral bending of the head of the wearer. The protective helmet therefore limits the degree of head movement before injury may occur. For instance, various limits of head movement can be defined as reported in the article titled “Normal Neck Range of Motion,” available online at [www.livestrong.com/article/95456-normal-neck-range-motion/]. Motion of the neck is measured from the neutral position, where the wearer is looking straight ahead with the head level. Ranges of motion for head movement can be defined as flexion, extension, rotation, and lateral bending. Flexion is the motion that allows the head to bend toward the chest. In normal flexion, one can touch the chin to the chest. Beginning in a neutral position, an acceptable range of motion for flexion is 40 to 60 degrees. Extension is tilting the head back. A normal range of motion will allow one to look at the ceiling. An acceptable measurement of range of motion from the neutral position is 45 to 70 degrees. Lateral bending is where one's neck is bent so that the ear leans toward the shoulder while looking straight ahead. Left bending is bringing the left ear toward the left shoulder, and right bending is moving the right ear toward the right shoulder. With normal range of motion, one should be able to move halfway between straight ahead and the shoulder, which is 45 degrees.

[0027] The lower portion of the protective helmet accordingly can be configured to provide various limits on ranges of motion. The lower portion can also be designed to accommodate various dimensions of other protective gear in limiting the ranges of motion. For example, the ranges of motion afforded by the lower portion can be tailored to account for other protective devices, such as shoulder pads, chest pads, neck pads, and/or back pads. In this way, the desired ranges of motion and limits thereof are retained in the presence of these other protective devices or pads. The lower portion of the protective helmet may also be integrated with or coupled to a face covering, such as a face mask or face shield, that protects the wearer's face, where the face covering can include a clear plastic shield or a metal reinforced or plastic grille to maintain visibility when wearing the helmet.

[0028] As noted, various ranges of motion can be limited by the lower portion. The lower portion can limit flexion by contacting a chest of the wearer. That is, downward and forward movement of the head toward the chest is arrested when the lower portion hits the wearer's chest. For example, the lower portion can limit flexion to less than about 60 degrees, or various increments down to 0 degrees, and in certain cases, flexion can be limited to less than about 50 degrees, 40 degrees, 30 degrees, 20 degrees, or 10 degrees. The lower portion can limit extension by contacting a back of the wearer. That is, the wearer's head can only tilt back so far due to the lower portion touching the wearer's back. For example, the lower portion can limit extension to less than about 70 degrees, or various increments down to 0 degrees, and in certain embodiments, extension can be limited to less than about 60 degrees, 50 degrees, 40 degrees, 30 degrees, 20 degrees, or 10 degrees. The lower portion can limit lateral bending by contacting a shoulder of the wearer. For example, the lower portion can limit lateral bending to less than about 45 degrees, or various increments down to 0 degrees, and in certain cases, lateral bending can be limited to less than about 35 degrees, 25 degrees, 15 degrees, or 5 degrees.

[0029] In some embodiments, the lower portion can include one or more tethers that couple the shell to another portion of the wearer's body. For example, the lower portion can include at least one tether coupled the chest of the wearer, the back of the wearer, the left shoulder of the wearer, and/or the right shoulder of the wearer. In reference to these portions of the wearer's body, it is understood that the tether(s) is coupled to a garment worn by the wearer at the aforementioned locations, a harness worn by wearer, or other protective device worn by the wearer, such as a chest pad, back pad, neck pad, shoulder pads, and the like. The tether can take the form of various fabrics, plastics, or other materials and can be configured as straps, mesh, sheets, or a whole or partial collar.

[0030] The helmet provided by the present technology can protect a wearer's head and may reduce the effect of an impact on the wearer's skull, neck, and/or spine. Likewise, when an elastomeric shell is employed, deformation and absorption of the impact can lessen the blow to an opposing player that impacts the wearer. For example, the effect of a helmet-to-helmet impact may be reduced for the opposing player as well as the wearer.

[0031] With reference now to FIGS. 1A and 1B, an embodiment of a helmet 100 is shown in cross-section on a wearer's head 105. The helmet 100 includes a shell 110 that is configured to receive the wearer's head 105. The shell 110 comprises an elastomeric material having a Young's modulus that is less than the Young's modulus of polycarbonate. A single pad 115 is coupled to an interior 120 of the shell 110 and configured to be positioned between the wearer's head 105 and the shell 110. The shell 110 has apertures 125 that serve to vent the helmet 100 and to facilitate hearing by the wearer. A chin strap 130 helps to secure the helmet 100 to the wearer's head 105. The pad 115 is a fluid filled bladder that includes a valve 135 for filling and withdrawing fluid. A face covering 140, such as a face shield or face mask, is coupled to the shell 110.

[0032] Another embodiment of a helmet 200 is shown in FIGS. 2A and 2B with the helmet 200 again shown in cross-section on the wearer's head 205. A shell 210 receives the wearer's head 205 and a plurality of pads 215 are coupled to an interior 220 of the shell 210. Apertures 225 in the shell 210 allow for air venting and facilitate hearing when using the helmet 200. Retention of the helmet 200 to the wearer's head 205 is improved by a chin strap 230. The pads 215 are fluid filled bladders that are interconnected by valves 235 that fluidly couple one bladder to another bladder and can regulate the rate of fluid transfer between bladders. To protect the wearer's face, a face covering 240 is coupled to the shell 210.

[0033] A further embodiment of a helmet 300 according to the present technology is shown in FIGS. 3A, 3B, 3C, and 3D. FIGS. 3A and 3B show the helmet 300 in cross-section so that the wearer's head 305 is visible and FIGS. 3C and 3D show the exterior of the helmet 300 when worn by the wearer. A shell 310 receives the wearer's head 305 and a plurality of fluid filled bladders 315 is coupled to the interior 320 of the shell 310. A plurality of apertures 325 in the shell 310 serve to vent the helmet 300 and help the wearer to hear, and a chin strap 330 aids in securing the helmet 300 to the wearer's head 305. The plurality of fluid filled bladders 315 are fluidly coupled to each other by valves 335 that can regulate fluid transfer between interconnected bladders 315. A face covering 340 is coupled to the shell 310 and protects the wearer's face while allowing for visibility. A lower portion 345 of the helmet 300 is coupled to the shell 310 and is configured to limit flexion, extension, and lateral bending of the wearer's head 305.

[0034] Turning now to FIGS. 4A, 4B, 4C, and 4D, yet another embodiment of a helmet 400 according to the present technology is shown. An elastomeric shell 410 receives a wearer's head (not visible in the figures) and at least one pad (not visible in the figures) is coupled to the interior of the elastomeric shell 410 and is positioned between the wearer's head and the elastomeric shell 410. Coupled to the shell 410 is a face covering 440 that protects the wearer's face while permitting a desired field of vision. A lower portion 445 is coupled to the elastomeric shell 410 and is configured to limit flexion, extension, and lateral bending of the wearer's head.

[0035] The elastomeric shell 410 and the lower portion 445 operate to mitigate the effects of various impacts to the wearer's head. For example, an impact at a top region of the wearer's head, as depicted in FIG. 4A by block arrow 450, can be partially absorbed by the elastomeric shell 410 as the elastomeric shell deforms as shown at 455. It should be noted that impacts to other regions of the elastomeric shell 410, including a front region, a back region, a left region, and a right region, can also be partially absorbed by the elastomeric shell 410 as it deforms in a similar fashion as shown at 455. The elastomeric shell 410 can be made of rubber, for instance, where the deformed portion of the shell at 455 returns to its original shape following the impact 450. Where the impact is at a back region of the wearer's head, shown by block arrow 460 in FIG. 4B, the lower portion 445 limits flexion by contacting the wearer's chest 465 when the wearer's head moves forward and downward, thereby preventing further movement. The lower portion 445 can be configured to limit flexion to angle alpha shown in FIG. 4B. The angle alpha can be less than about 60 degrees, or can be further limited as desired to any increment between about 60 degrees and about 0 degrees, where substantially no forward and downward movement is permitted at 0 degrees, FIG. 4C shows an impact at a front region of the wearer's head at block arrow 470, causing the head to move backward and downward where the lower portion 445 limits extension by contacting the wearer's back 475 and preventing further movement. The lower portion 445 can be configured to limit extension to angle beta shown in FIG. 4C. The angle beta can be less than about 70 degrees, or can be further limited as desired to any increment between about 70 degrees and about 0 degrees, where substantially no backward and downward movement is permitted at 0 degrees. As shown in FIG. 4D, an impact at a side region of the wearer's head, depicted by block arrow 480 at the right region of the wearer's head, can result in lateral bending that is limited by the lower portion 445 contacting a shoulder 485 of the wearer. The lower portion 445 can be configured to limit lateral bending to angle gamma shown in FIG. 4D. The angle gamma can be less than about 45 degrees, or can be further limited as desired to any increment between about 45 degrees and about 0 degrees, where substantially no lateral movement is permitted at 0 degrees.

[0036] With reference to FIG. 5, still another embodiment of the present technology includes a helmet 500 having a shell 510, a face covering 540 coupled to the shell 510, and a lower portion configured to limit flexion, extension, and lateral bending of the wearer's head that has tethers 590 coupled to the wearer's chest 565 and back 575. The tether 590 coupled to the wearer's chest 565 limits extension by preventing the wearer's head from moving backward and downward. The other tether 590 coupled to the wearer's back 575 limits flexion by preventing the wearer's head from moving forward and downward. The tethers 590 can be made of various fabrics, plastics, or other materials and can be configured as straps, mesh, sheets, or a whole or partial collar.

[0037] Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms, and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. Equivalent changes, modifications and variations of some embodiments, materials, compositions and methods can be made within the scope of the present technology, with substantially similar results.