Helmet impact liner system

[0001] This application is a U.S. Non-Provisional Patent Application which claims priority to U.S. Provisional Patent Application No. 61/641,619, filed on May 2, 2012 and titled “Helmet Impact Liner System,” which is hereby incorporated by reference in its entirety.

[0002] Helmets generally include a shell and a liner. The helmet shell provides protection from protruding objects and is often configured to spread the impact load across the footprint of the helmet. The helmet liner is generally made of a softer and lower density material than the helmet shell. The helmet liner is often configured such that, upon impact, the helmet liner at least partially absorbs the impact energy from the force of an impact.

[0003] The present application discloses a helmet, an impact liner system for a helmet, and energy management structures for a helmet. The helmet generally comprises a helmet shell and an impact liner system removably attached to the helmet shell. In certain embodiments, the impact liner system comprises a plurality of compressible energy management structures and one or more carriers for supporting the energy management structures within the helmet shell. The energy management structures are positioned between an interior surface of the helmet shell and the head of a user when the impact liner system is attached to the helmet shell. Each energy management structure comprises an outer wall and an inner wall substantially surrounded by the outer wall. The outer and inner walls are configured to bend when the exterior of the helmet shell is impacted by an object. The one or more carriers comprise a plurality of openings, each opening configured to receive an energy management structure. Further, the outer wall of the energy management structures extend between the interior of the helmet shell and the carrier of the impact liner system.

[0004] In certain embodiments, the energy management structures comprise a bottom portion and a top portion attached to the bottom portion. The bottom portion comprises a bottom wall and an outer wall extending from the bottom wall. The top portion comprises a top wall and inner wall extending from the top wall toward the bottom wall. The outer wall extends between the bottom wall and the top wall. Further, the energy management structure is configured to be positioned between the head of user and an interior surface of a helmet shell such that the top wall is adjacent the head of the user and the bottom wall is adjacent the interior surface. The outer and inner walls are configured to bend when an exterior of the helmet shell is impacted by an object.

[0005] These and additional embodiments will become apparent in the course of the following detailed description.

[0030] The present application discloses a helmet, an impact liner system for a helmet, and energy management structures for a helmet. The impact liner system generally comprises a plurality of compressible energy management structures that line the interior of the helmet shell and are positioned between the user's head and the helmet shell. In the embodiments disclosed herein, the impact liner system is described for use with a military helmet shell. Examples of such military helmet shells include a US Army Advanced Combat Helmet (ACH), a US Marine Corp Lightweight Helmet (LWH), an Enhanced Combat Helmet (ECH), a Personal Armor System for Ground Troops (PASGT) helmet, or other typical ballistic helmet shells.

[0031] However, the impact liner system of the present application may also be used with a variety of other helmets, including, but not limited to, sporting helmets, such as football, lacrosse, hockey, multi-sport, cycling, softball, or baseball helmets, or safety helmets, such as industrial or construction helmets. Additionally, the impact liner system of the present application may be used as an impact or energy management structure in a variety of other applications, such as, for example, vehicle or aircraft seating, vehicle occupant padding, and floor padding of workplace or recreational facilities. Furthermore, the impact liner of the present application may be used to protect other parts of the body.

[0032] During an impact event, the head of the user may experience peak accelerations or “g” forces. This may occur, for example, when the head comes to a sudden or violent stop within the helmet. The impact liner system of the present application is configured to manage the acceleration response of the user's head and minimize the amount of peak accelerations experienced by the user during an impact event. “Acceleration”, as used herein, describes both acceleration and deceleration.

[0033] For example, the impact liner system of the present application may be configured to provide one or more stiffness responses such that the head of the user is gently accelerated to a stop. The one or more stiffness responses may be provided by a variety of different structures and/or materials of the impact liner system. The impact liner system may also be “tunable” to provide a range of stiffness responses. One exemplary method of “tuning” the impact liner system is to use various combinations of structures and materials for the components of the impact liner system. For example, structures and/or materials of a first portion of an energy management structure may differ from a second portion of the energy management structure. Further, the impact liner system may comprise one or more pads having a different stiffness response than the energy management structure.

[0034] The impact liner system of the present application may also comprise a carrier system for supporting and positioning the compressible energy management structures within the helmet shell. The energy management structures may be removably attached to the carrier system such that one or more of the energy management structures may be removed from the carrier system and replaced with a similar or different energy management structure. Further, the carrier system may also be removed from the helmet shell and replaced with a similar or different carrier system. As such, the impact liner system may be configured for use in a variety of different applications.

[0035] FIGS. 1 and 1A illustrate an impact liner system 100 according to an embodiment of the present invention. As shown, the impact liner system 100 is attached to the interior or backface of a helmet shell 110 and is configured to be positioned between the user's head and the helmet shell. The impact liner system 100 comprises a plurality of energy management structures 112 removably attached to one or more carriers 114 and 116. As illustrated in FIG. 1, the carriers 114 and 116 are configured such that the energy management structures 112 line the interior of a helmet shell 110, including the front, rear, crown and side portions of the helmet. The plurality of energy management structures 112 are configured to bend, buckle, crush, and/or otherwise deform upon impact to absorb and/or dissipate the impact energy from the force of the impact.

[0036] The carriers of the present application may be configured in a variety of ways to position the energy management structures at various locations and in various concentrations within the helmet shell. Carriers of various shapes, sizes, and opening layouts may be used to configure the impact liner system in variety of ways, such as for use in different helmets or to provide different amounts of coverage and spacing between the energy management structures. For example, the carriers of the impact liner system may be configured such that energy management structures are more concentrated at critical impact locations. Thus, the impact liner system may be reconfigured by simply using a different carrier layout.

[0037] FIGS. 2A-3B illustrate the carriers 114 and 116 of the impact liner system 100. Each carrier 114 and 116 comprises an array of openings configured to receive one or more energy management structures of the present application.

[0038] As illustrated in FIGS. 2A and 2B, the carrier 114 comprises twelve (8) openings in a 2×4 pattern and is curved to extend around the front and/or the rear of the helmet shell 110 and at least partially around the sides of the helmet shell. As such, the carrier 114 is sized and configured such that the energy management structures 112 line the portions of the helmet shell 110 corresponding to the front and side temple portions of the user's head and/or the rear and sides of the user's head. As illustrated in FIGS. 3A and 3B, the carrier 116 comprises seven (7) openings in a combined 1×3 and 2×2 pattern configured line the portion of the helmet shell 110 corresponding to the crown of the user's head.

[0039] As illustrated in FIG. 1, the impact liner system 100 is attached to the interior or backface of a helmet shell 110 by the energy management structures 112. As illustrated in FIGS. 2A-3B, the bottom of one or more of the energy management structures 112 comprises an attachment feature 220 for removably attaching the energy management structure and the corresponding carrier 114 and 116 to the interior or backface of the helmet shell 110. As shown, the attachment feature 220 is a piece of Velcro® (e.g., hook fabric or loop fabric) that is configured to mate with a corresponding piece of Velcro® (e.g., loop fabric or hook fabric) on the interior of the helmet shell 110 to removably attach the energy management structure 112 and the corresponding carrier 114 and 116 to the helmet shell. However, a wide variety of other attachment features may be used to attach one or more of the energy management structures 112 to the interior of the helmet shell 110. Examples of attachment features that may be used include, but are not limited to, one or more fasteners, adhesive, clips, pins, snaps, tape, buckles, hook and loop, or pin and slot. Further, in certain embodiments, one or more of the energy management structures 112 are attached to the interior of the helmet shell 110 with the attachment feature 220 but without being attached to a carrier 114 and 116 of the impact liner system 100 and/or without being connected to another energy management structure.

[0040] In certain embodiments, the carriers of the impact liner system may be removably attached to the helmet shell. For example, one or more of the carriers may comprise features or bosses with openings for attachment of the carrier to the helmet shell. In one exemplary embodiment, one or more of the carriers comprise a flanged portion extending from the carrier that is shaped and configured to facilitate attachment of the carrier to the helmet shell. The flanged portions may comprise one or more attachment features, such as, for example, one or more fasteners, adhesive, clips, pins, snaps, tape, buckles, Velcro®, or a hook and loop, used to attach the flanged portion to the helmet shell. It should be understood that the bosses and flanged portions of the carriers described herein are exemplary and the carriers may be configured in a variety of other ways to be removably attached to the interior of the helmet shell. For example, the carriers may be installed in the interior of the helmet shell with one or more fasteners, adhesive, weld, clips, pins, snaps, tape, buckles, Velcro®, or a hook and loop. Further, the carriers may be attached to the helmet shell by tabs that are bolted or otherwise attached at a mounting point, such as, for example, with a bolt that goes through the helmet shell to attach a chinstrap as well as the impact liner system to the helmet shell.

[0041] As illustrated in FIGS. 1-3B, the openings in the carriers 114 and 116 are circular in shape and the energy management structures 112 comprise cylindrical outer walls sized and configured to be received in the openings. However, it should be understood that the carriers of the present application may comprise openings of various shapes and sizes to accommodate a variety of energy management structures, including any one or more of the energy management structures described herein. Further, the carriers of the present application may be configured to position energy management structures of various shapes and sizes at variety of locations and in a variety of concentrations within the helmet shell. In certain embodiments, the carriers of the impact liner system may also comprise a plurality of openings or slots that permit air to circulate between the head of the user and the helmet shell to facilitate cooling of the user's head.

[0042] As illustrated in FIGS. 1 and 1A, the energy management structures 112 are positioned in the carriers 114 and 116 such that the top of the energy management structure is facing the head of the user and the base or bottom or the energy management structure is facing the backface of the helmet shell 110. However, in other embodiments, one or more of the energy management structures 112 may be positioned such that the top of the structure is facing the backface of the helmet shell 110 and the base or bottom is facing the user's head.

[0043] Further, the energy management structures of the present application may be removably secured in the openings of the carriers in a variety of ways, such as, for example, with a friction or interference fit, one or more fasteners, adhesive, clips, pins, snaps, tape, buckles, Velcro®, or a hook and loop. For example, as illustrated in FIGS. 2A and 3A, the energy management structures 112 comprise one or more resilient protrusions 222 extending outward from the outer wall of the structure. When the energy management structures 112 are inserted into the carrier openings, the edge of the opening slides over the one or more protrusions 222 and is positioned between the protrusions and a flange of the energy management structure. As such, the energy management structures 112 snap into the openings of the carrier 114 and 116 and are removably secured in the opening.

[0044] In some embodiments, the energy management structures of the present application may be integrally formed with the carriers. For example, the energy management structures may be integrally molded with the carriers such that the carrier forms a common base for the structures. Further, the energy management structures and the carriers may be RF welded together. For example, a flange of the energy management structure may be welded to the radial portion around an opening in the carrier to secure the energy management structure within the opening. In some embodiments, the carriers do not have openings and the energy management structures are attached directly to the carrier. The energy management structures may be attached to the carriers in a variety of ways, such as, for example, with one or more fasteners, adhesive, weld, clips, pins, snaps, tape, buckles, Velcro®, or a hook and loop.

[0045] Each carrier of the present application is generally formed from a single piece of material. However, any one or more carriers may comprise a plurality of components integrally formed or otherwise secured together. Further, the carriers may be formed from a variety of materials capable of supporting the energy management structures of the present application, such as, for example, thermoplastic polymers including polyurethanes (TPU), polyethylene, polycarbonate, and Acrylonitrile butadiene styrene (ABS). In certain embodiments, the carriers are made from thermoplastic polyurethane BASF Elastollan 1164D53. Further, the carriers of the present application are generally between about 0.025 inch and about 0.100 inch thick. In certain embodiments, the carriers are about 0.040 inch thick.

[0046] The energy management structures of the present application may be a variety of shapes and configurations. For example, the energy management structures may comprise one or more walls that are configured to bend, buckle, crush, or otherwise deform upon impact to absorb and/or dissipate the impact energy from the force of the impact. The one or more walls of the energy management structure may take a variety of different forms. For example, the walls may form a cylinder, truncated cone, or hemisphere and may comprise one or more cross sections shaped as a circle, rectangle, square, trapezoid, hexagon, diamond, helix, or other shape. The walls of the energy management structures may also be bowed or curved. In addition, inserts or other structures, such as foam inserts or various polymer structures, may be placed within the energy management structure and may or may not be attached to the energy management structure or carrier.

[0047] FIGS. 4A-10B illustrate various exemplary embodiments of energy management structures of the present application. The energy management structures are generally removably attached to a carrier of the impact liner system and positioned between the backface of the helmet shell and the user's head. The energy management structures are configured such that they compress during an impact event to absorb and/or dissipate the impact energy from the force of the impact.

[0048] The energy management structures illustrated in FIGS. 4A-10B generally comprise an outer vertical wall and an inner structure having a vertical wall. Upon impact, the energy management structure compresses and the outer vertical wall will bend, buckle, crush, or otherwise deform to absorb and/or dissipate the impact energy from the force of the impact. Further, once the energy management structure is compressed to a certain point, the vertical wall of the inner structure will also bend, buckle, crush, or otherwise deform to further absorb and/or dissipate the impact energy.

[0049] During an impact event, the vertical wall of the inner structure will act as “stop” once the outer vertical wall is compressed to a certain point and the bottom of the vertical wall contacts the helmet shell. In this regard, the vertical wall of the inner structure will prohibit further stress on the outer vertical wall, thereby prohibiting excessive plastic (i.e., permanent) deformation and improving performance for multiple high compression impacts. Further, during an impact event, the vertical wall of the inner structure will work in concert with the outer vertical wall to produce an overall compressive response profile of the energy management structure. The compressive response profile of the outer vertical wall will be added to the compressive response profile of the vertical wall of the inner structure to produce the overall compressive response profile of the energy management structure.

[0050] The energy management structures illustrated in FIGS. 4A-7D comprise a base portion 450 having a bottom wall 452 and a cylindrical vertical wall 454 extending from the bottom wall and about a vertical axis of the structure. Furthermore, the base portion 450 comprises a radial flange 456 extending outward from the vertical wall 454 and about the vertical axis. As shown, the bottom wall 452 of the base portion 450 comprises a central opening 458 substantially aligned with the vertical axis and a plurality of slotted openings 460 spaced radially about the vertical axis.

[0051] As illustrated in FIGS. 4A-7D, the base portion 450 also comprises one or more protrusions 462 extending outward from the cylindrical vertical wall 454 to facilitate placement and attachment of the structure within an opening in a carrier 114 and 116 of the impact liner system 100. When the energy management structure is inserted into the carrier opening, the edge of the opening slides over the one or more protrusions 462 and is positioned between the protrusions and the flange 456 of the base portion 450. As such, the energy management structure snaps into the opening of the carrier 114 and 116 and is removably secured in the opening.

[0052] The base portion 450 may take a variety of different forms. For example, in certain embodiments, the vertical wall of the base portion may form a truncated cone or hemisphere and may comprise one or more cross sections shaped as a circle, rectangle, square, trapezoid, hexagon, diamond, helix, or other shape. The vertical wall of the base portion may also be bowed or curved in certain embodiments. Further, the bottom wall of the base portion may have more or less openings of various shapes and sizes located anywhere on the bottom wall. In certain embodiments, the openings in the bottom wall are spaced around an attachment feature (e.g., a piece of Velcro®) on the bottom wall that may be used to removably attach the energy management structure to the helmet shell. As such, the attachment feature does not prohibit airflow through the energy management structure. In certain embodiments, the bottom wall does not have any openings.

[0053] The energy management structures illustrated in FIGS. 4A-7D also comprise a top portion or cap that is attached to the base portion 450. Each top portion comprises top wall and an inner structure. The inner structure has a vertical wall that extends from the top wall and about the vertical axis of the energy management structure. When the top portion is attached to the bottom portion 450, the inner structure is inserted into the base portion such that the vertical wall 454 of the base portion surrounds the vertical wall of the top portion.

[0054] The energy management structures illustrated in FIGS. 4A-7D have an inner structure with an open bottom. However, in certain embodiments, the inner structure may comprise a bottom wall and may or may not include one or more openings in the bottom wall and/or the vertical wall. Further, as shown, the top wall comprises a central opening substantially aligned with the vertical axis and a plurality of openings spaced radially about the vertical axis. However, the top portion may have more or less openings of various shapes and sizes located anywhere on the top wall. In certain embodiments, the top wall does not have any openings.

[0055] FIGS. 4A-4D illustrate an exemplary energy management structure 400 comprising a top portion 404 having an inner structure with a vertical wall 410 shaped as a truncated cone. The vertical wall 410 extends from a top wall 406 of the top portion 404 and about a vertical axis 402 of the energy management structure 400. The angle A₁ of the vertical wall 410 with respect to the vertical axis 402 is generally between about 0 and about 60 degrees. In certain embodiments, the angle A₁ is about 20 degrees.

[0056] FIGS. 5A-5D illustrate an exemplary energy management structure 500 comprising a top portion 504 having an inner structure with a vertical wall 510 shaped as a truncated cone. The vertical wall 510 extends from a top wall 506 of the top portion 504 and about a vertical axis 502 of the energy management structure 500. As shown, the vertical wall 510 extends a greater distance from the top wall 506 than the vertical wall 410 extends from the top wall 406. The angle A₂ of the vertical wall 510 with respect to the vertical axis 502 is generally between about 0 and about 60 degrees. In certain embodiments, the angle A₂ is about 20 degrees.

[0057] The energy management structures 400 and 500 provide an improved off-axis impact response (i.e., non-perfect vertical compression). This occurs because the conical shape of the inner structure provides the ability to deform with more wall buckling than wall bending when compressed off-axis. This wall buckling results in a stiffer response or higher resistance to compression than bending, which allows mitigation of higher energy impacts. While a cylindrical wall provides a more optimal buckling mode than a conical wall in a pure axial compression, the cylindrical wall is put into a bending rather than buckling mode when compressed off-axis. This bending mode typically provides much less resistance to compression, i.e. the structure collapses rather than mitigating the impact. The buckling mode of a conical wall prohibits this collapsing effect for a greater range of impact angles (off-axis) than a cylindrical wall; and further, the outer structure aids in stabilizing the inner structure and maintaining the preferable higher-stiffness buckling mode.

[0058] As illustrated in FIGS. 4A and 5A, the top portions 404 and 504 of the energy management structures 400 and 500 comprise a central opening 408 and 508 substantially aligned with the vertical axis 402 and 502 and a plurality of smaller openings 412 and 512 spaced radially about the vertical axis. The openings permit air to escape from within the structure during impact. The openings are sized and configured such that the exiting of the air during impact does not affect the compressive behavior of the structure. Further, the openings permit air to circulate through the energy management structure to facilitate cooling of the user's head.

[0059] The top portion of the energy management structures may have any number of openings of various shapes and sizes located at various locations on the top wall. For example, FIGS. 7A-7D illustrate an exemplary energy management structure 700 that is similar to the energy management structure 400. However, a top portion 704 of the energy management structure 700 comprises a plurality of slotted openings 712 of various sizes spaced radially about a vertical axis 702 of the structure and at various distances from the vertical axis. The energy management structure 400 comprises circular openings 412 spaced radially about the vertical axis 402 at substantially the same distance. In certain embodiments, the openings in the top wall of the energy management structure are spaced around an attachment feature (e.g., a piece of Velcro®) on the top wall that may be used to removably attach a pad or other item to the energy management structure. As such, the attachment feature does not prohibit airflow through the energy management structure. Furthermore, in certain embodiments, the top wall may not have any openings.

[0060] As illustrated in FIGS. 4B and 5B, the distance D₁ between the bottom of the vertical wall 410 and the bottom of the vertical wall 454 of the base portion 450 is generally between about 0 and about 0.75 inch and the distance D₂ between the bottom of the vertical wall 510 and the bottom of the vertical wall 454 of the base portion 450 is generally between about 0 and about 0.25 inch. In certain embodiments, the distance D₁ is about 0.35 inch and the distance D₂ is about 0.050 inch. However, the distance between the bottom of the inner structure vertical wall and the bottom of the outer vertical wall may be more or less in other embodiments depending on the particular application of the impact liner system. For example, in certain embodiments, the bottom of the inner structure vertical wall may extend below the bottom of the outer vertical wall.

[0061] FIGS. 6A-6D illustrate an exemplary energy management structure 600 comprising a top portion 604 having an inner structure with a cylindrical vertical wall 610. The vertical wall 610 extends from a top wall 606 of the top portion 604 and about a vertical axis 602 of the energy management structure 600. The distance D₃ between the bottom of the vertical wall 610 and the bottom of the vertical wall 454 of the base portion 450 is generally between about 0 and about 0.75 inch. In certain embodiments, the distance D₃ is about 0.050 inch. Similar to the energy management structures 400 and 500, the top wall 606 comprises a central opening 608 substantially aligned with the vertical axis 602 and a plurality of smaller openings 612 spaced radially about the vertical axis. The openings permit air to escape from within the structure during impact. The openings are sized and configured such that the exiting of the air during impact does not affect the compressive behavior of the structure. Further, the openings permit air to circulate through the energy management structure to facilitate cooling of the user's head.

[0062] An inner structure with a cylindrical vertical wall provides several advantages. A cylindrical geometry provides a higher crush strength than conical geometry; however, a cylindrical inner structure may be more prone to collapsing off-axis if the compression forces are not aligned perpendicular to the center axis of the inner structure. The relatively small aspect ratio of diameter-to-height may make the inner cylinder prone to collapsing onto its' side, but the outer structure provides stability to ensure a high stiffness buckling mode occurs during compression. Additionally, the use of the inner cylindrical structure allows for the use of two types of material, one for the outer wall and one for the inner wall, to achieve a unique overall compressive response. This can be used to balance properties such as temperature operating range, or compressive strength versus multi-compression durability.

[0063] The top portion of the energy management structures may be attached to the base portion in a variety of ways and may or may not be removable from the base portion. For example, the top portion may be attached to the base portion with a friction or interference fit, fastener, clip, pin, projection, snap, buckle, adhesive, tape, Velcro®, hook and loop, pin and slot, or the like. The top portion may also be integrally formed with the base portion or separately formed and RF welded to the base portion. As illustrated in FIGS. 4A-7D, the radial flange 456 of the base portion 450 comprises a channel 462 sized and configured to mate with a corresponding projection on the top portion (see, e.g., projections 480, 580, 680, and 780). The projection mates with the channel 462 to align the top portion relative to the base portion 450. Further, the channel 462 and projection may be used to facilitate welding of the top portion to the base portion 450. The channel 462 and projection may also be sized and configured to form a friction or interference fit to removably couple the top portion to the base portion 450.

[0064] FIGS. 8A and 8B illustrate an exemplary energy management structure 800 according to an embodiment of the present application. The energy management structure 800 comprises a top wall 810 and a cylindrical vertical wall 812 extending from the top wall and about a vertical axis 802 of the structure. Furthermore, the energy management structure 800 comprises a radial flange 814 extending outward from the vertical wall 812 and about the vertical axis 802. The top wall 810 comprises a central opening 816 aligned with the vertical axis 802 and a plurality of openings 818 spaced radially about the vertical axis.

[0065] The energy management structure 800 also comprises one or more protrusions 820 extending outward from the cylindrical vertical wall 812 to facilitate placement and attachment of the structure within an opening in a carrier of the impact liner system. When the energy management structure 800 is inserted into the carrier opening, the edge of the opening slides over the one or more protrusions 820 and is positioned between the protrusions and the flange 814 of the energy management structure. As such, the energy management structure 800 snaps into the opening of the carrier and is removably secured in the opening.

[0066] FIGS. 9A and 9B illustrate an energy management structure 900 according to an embodiment of the present application. The energy management structure 900 comprises a top wall 910 and a bowed or curved cylindrical vertical wall 912 extending from the top wall and about a vertical axis 902 of the structure. Furthermore, the energy management structure 900 comprises a radial flange 914 extending outward from the vertical wall 912 and about the vertical axis 902. The top wall 910 comprises a central opening 916 aligned with the vertical axis 902 and a plurality of openings 918 spaced radially about the vertical axis. The energy management structure 900 also comprises one or more protrusions 920 extending outward from the vertical wall 912.

[0067] As illustrated in FIGS. 8A-9B, each energy management structure 800 and 900 comprises an inner structure having a vertical wall 830 and 930 shaped as a truncated cone and extending from the top wall 810 and 910 and about the vertical axis 802 and 902 of the structure. The angle A₃ of the vertical wall 830 is between about 0 and about 60 degrees with respect to the vertical axis 802 and the angle A₄ of the vertical wall 930 is between about 0 and about 30 degrees with respect to the vertical axis 902. In one embodiment, the angle A₃ is about 30 degrees and the angle A₄ is about 20 degrees.

[0068] As illustrated in FIGS. 8B and 9B, the distance D₄ between the bottom of the vertical wall 830 and the bottom of the vertical wall 812 is between about 0 and about 0.75 inches and the distance D₅ between the bottom of the vertical wall 930 and the bottom of the vertical wall 912 is between about 0 and about 0.75 inches. In one embodiment, the distance D₄ is about 0.5 inches and the distance D₅ is about 0.050 inches. However, the distance between the bottom of the inner structure and the bottom of the outer vertical wall may be more or less in other embodiments depending on the particular application of the impact liner system.

[0069] FIGS. 10A and 10B illustrate an energy management structure 1000 according to an embodiment of the present application. As shown, the energy management structure 1000 comprises a top wall 1010 and a diamond shaped vertical wall 1012 extending from the top wall. A flange 1014 extends outward from the vertical wall 1012 at a top end of the structure. The top wall 1010 comprises a central opening 1016 aligned with a vertical axis 1002 of the energy management structure 1000. The top wall 1010 also comprises a plurality of smaller openings 1018 configured to permit air to escape from within the structure 1000 during impact. Further, the openings 1016 and 1018 may permit air to circulate through the energy management structure 1000 to facilitate cooling of the user's head.

[0070] As illustrated in FIGS. 10A and 10B, the energy management structure 1000 also comprises an inner structure having a vertical wall 1030 shaped as a truncated cone and extending from the top wall 1010 and about the vertical axis 1002 of the structure. The angle A₅ of the vertical wall 1030 with respect to the vertical axis 1002 is between about 0 and about 60 degrees. In one embodiment, the angle A₅ is about 5 degrees. Further, the distance D₆ between the bottom of the vertical wall 1030 and the bottom of the vertical wall 1012 is between about 0 and about 0.7 inches. In one embodiment, the distance D₆ is about 0.25 inches. However, the distance between the bottom of the inner structure and the bottom of the outer vertical wall may be more or less in other embodiments depending on the particular application of the impact liner system.

[0071] Upon impact, the energy management structure 1000 compresses and the diamond shaped vertical wall 1012 will bend, buckle, crush, or otherwise deform to absorb and/or dissipate the impact energy from the force of the impact. Further, once the energy management structure 1000 is compressed to a certain point, the vertical wall 1030 of the inner structure will bend, buckle, crush, or otherwise deform to further absorb and/or dissipate the impact energy. As such, the compression of the energy management structure 1000 provides a first and second stiffness response that permits the head of the user to gently accelerate to a stop after impact.

[0072] Certain energy management structures of the present application were compressed and the aggregate stiffness or compression curves corresponding to the compression of the energy management structures are shown in FIGS. 12 and 13. Specifically, FIG. 12 illustrates the compression of the closed base energy management structure 700 illustrated in FIGS. 7A and 7B. The energy management structure 700 having an outer diameter of about ½ inch was tested constructed of two different materials, BASF Elastollan 1164D and BASF Elastollan 1154D. The 1164D material has a 64 shore D durometer and is harder than 1154D which has a 54 shore D durometer. Further, the energy management structure 700 constructed of BASF Elastollan 1154D was tested with the pad structure 1400 attached to the top portion 704 (FIG. 14A). FIG. 13 illustrates the compression of the open base energy management structure 800 illustrated in FIGS. 8A and 8B and the open base energy management structure 900 illustrated in FIGS. 9A and 9B. The energy management structure 800 was tested constructed of two different materials, BASF Elastollan 1154D and BASF Elastollan S98A. The S98A material has a 98 shore A durometer and provides a stiffer response than the 1154D material. The energy management structure 900 was tested constructed of two different materials, BASF Elastollan 695A and BASF Elastollan 1195A, both are a 95 shore A hardness and exhibit similar compression profiles.

[0073] As illustrated in FIGS. 12 and 13, the stiffness or compression curves are changed by varying the material for the energy management structures. For example, as shown in FIG. 12, the energy management structure 700 constructed of the 1164D material provided a greater stiffness response than the structure constructed of the 1154D material. However, the structure 700 constructed of the 1164D material reached a point of plastic deformation at a lesser compressive strain than the structure constructed of the 1154D material. Similarly, as shown in FIG. 13, the energy management structure 800 constructed of the S98A material provided a greater stiffness response than the structure constructed of the 1154D material. However, the structure 800 constructed of the S98A material reached a point of plastic deformation at a lesser compressive strain than the structure constructed of the 1154D material. The ideal response of a structure depends on the specific application, for example in a helmet it must behave appropriately for the expected impact energy levels, multiple impact requirements, temperature operating range and other factors. It should be noted that the energy management structures can be made from different materials or similar materials in order to provide a more ideal curve for the actual loading application.

[0074] As illustrated in FIG. 12, the energy management structure 700 with the pad structure 1400 attached to the top portion 704 provided a softer initial crush response than the structure without the pad structure. In other words, the pad structure 1400 permits the energy management structure 700 to have an initial “give” or pliability. This initial “give” provides a comfort response to the overall performance of the energy management structure 700.

[0075] As illustrated in FIG. 13, the bowed or curved vertical wall 912 of the energy management structure 900 provides a softer initial crush response than that of the vertical wall 812 of the energy management structure 800. In other words, the bowed or curved vertical wall 912 permits the energy management structure 900 to have an initial “give” or pliability. This initial “give” provides a comfort response to the overall performance of the energy management structure 900. Along with this generally softer response, the bowed vertical wall 912 of the energy management structure 900 may be crushed further than the vertical wall 812 of the energy management structure 800 while still maintaining a nearly perfect elastic response (i.e., a full rebound or very minimal permanent deformation), thereby improving performance for multiple high compression impacts. The vertical wall 812 of the energy management structure 800 provides a greater stiffness response than the bowed vertical wall 912 of the energy management structure 900. This greater stiffness response is due to a more aggressive bending-deformation mode than the bowed vertical wall 912. However, in some embodiments, the vertical wall 812 of the energy management structure 800 may reach a point of plastic deformation at lesser compressive strains than the bowed vertical wall 912.

[0076] The outer vertical wall of the energy management structures of the present application generally have an outside diameter between about 0.5 inch and about 2.5 inches. In certain embodiments, the outside diameter of the outer cylindrical vertical wall of the energy management structure is about 1.2 inches. Further, the outer vertical wall of the energy management structures generally have a height between about 0.3 inch and about 1.75 inches. In certain embodiments, the height of the outer cylindrical vertical wall of the energy management structure is about 0.75 inch.

[0077] Any one or more vertical wall of the energy management structures may have a draft. The draft angle of the vertical wall may range between 0 degrees (i.e., no draft) and about 10 degrees. For example, FIG. 8B illustrates a draft angle A_D of the vertical wall 812 with respect to the vertical axis 802 of the energy management structure 800. In one embodiment, the draft angle A_D of the vertical wall 812 is about 3.0 degrees, i.e., each side of the wall is drafted 1.5 degrees from vertical.

[0078] The vertical wall thickness of the energy management structures may be selected to vary the stiffness of the structure. Further, the thickness of the vertical walls may be selected to vary the range of travel when the structure buckles upon impact, thus varying the bottom out strain of the structure. For example, the vertical wall thickness of the energy management structures of the present application may be between about 0.020 inch and about 0.125 inch to provide a desired stiffness of the structure. In one embodiment, the energy management structures have an average vertical wall thickness of about 0.0485 inch. For example, in one exemplary embodiment in which the vertical wall has a draft angle of about 3 degrees, the thickness at the base or bottom of the vertical wall is about 0.030 inch and the thickness at the top of the vertical wall is about 0.067. This vertical wall thickness provides a desired stiffness of the structure while maximizing the bottom out strain of the structure. Further, the top and/or bottom wall thickness of the energy management structures of the present application may be between about 0.020 and about 0.125 inch. In certain embodiments, the energy management structures have a consistent vertical wall thickness that is drafted evenly, e.g., 1.5 degrees in the same direction on each side of the wall, giving a top vertical wall thickness of about 0.030 inch and a bottom vertical wall thickness of about 0.030 inch, which is the case for the closed base structures shown in FIGS. 4B, 4D, 5B, 5D, 6B, 6D, 7B and 7D, and the wall thickness of the flange is about 0.035 inch.

[0079] The energy management structures of the present application may comprise a variety of materials. For example, the material of the energy management structures may range from soft elastomers to stiff thermoplastics and thermosets or even metals. In one embodiment, the energy management structures are made from a thermoplastic polyurethane (TPU). More specifically, the energy management structures are made from a grade of BASF Elastollan including 1154D53, 1164D53, 1174D53, or other grades of Elastollan using either polyether or polyester base polyols, additionally other TPUs may be used such as Bayer Texin, DuPont Bexloy, or Merquinsa Pearlthane. However, the energy management structures may be made from a variety of other thermoplastic elastomers (TPE), such as olefin based TPE's like Santoprene or Arnitel, thermoplastic copolyesters (COPE) such as RTP 1500, polyether block amide elastomers such as Pebax, silicon based chemistries, or engineering resins such as PEEK or Ultem. Further, in some embodiments, thermoset elastomers may be used. Other materials that may be used include Dupont Hytrel, Dupont ETPV, or impact modified 6/6 nylon. Structures made with different materials or different grades of the same material may be used together in the same liner; this can aid in tuning the liner for optimal performance across multiple impact locations.

[0080] The material used for the energy management structures may be selected based on a variety of characteristics. For example, the material may be selected based on its response to varying temperatures. A material may be selected based on its performance across a range of temperatures and the environment in which the impact liner system will likely be used. In some embodiments, the material of the energy management structures may be selected to counteract the negative changes of other helmet components, such as the stiffening of a helmet shell in colder conditions.

[0081] The material of the energy management structures may also be selected based on its strain rate sensitivity. For example, a highly strain rate sensitive material may permit varying degrees of rate stiffening in the energy management structures during the varying deformation modes. Such a material may be used to provide an energy management structure that acts stiffer in an impact event and softer when the collision is not at impact rates or in lower velocity hits. This may be advantageous when compared to other helmet materials which may stiffen 2 to 3 times at impact rates when compared to nearly static loading, but do not show appreciable stiffening when loaded at two rates that are not greatly disparate.

[0082] The material of the energy management structures may also be selected based on the particular application or performance requirements. For example, military helmet (ACH) performance testing requires the impact liner to perform ideally at 17 ft/sec, 14 ft/sec, and 10 ft/sec impact velocities. Although not dramatic changes in velocity, given the mass of the head form there is a 2 to 3 times increase in kinetic energy. As such, a material of the energy management structures may be selected that stiffens at 2 to 3 times across that range of velocities.

[0083] The energy management structures are generally injected molded from a single piece of material. However, in some embodiments, the energy management structures may be made from a plurality of components. The multiple components may be injection molded and may be RF welded together. Other methods for fabricating and assembling the energy management structures may also be used, such as, for example, ultrasonic, heat staking, co-molding, insert molding, thermoforming, or rotomolding. Void spaces within the structure may also be filled with foam or other padding or elastomeric material to alter the compression response of the structure, generally by adding stiffness to the structure. The filler material may be pre-fabricated to shape and press-fit or adhered in place. The filler material may also be poured or formed in place within each structure.

[0084] Furthermore, the stiffness of the energy management structures of the present application is not dependent on packing density or a combination of packing density and chemistry. Thus, the overall stiffness response of the impact liner system may be increased without dramatically increasing the weight of the helmet. This provides an advantage over energy absorbing materials, such as foam, in which the density of the material may have to dramatically increase depending on the application and required stiffness, thus increasing the weight of the helmet. In many applications, such as performance applications, it is advantageous to modify stiffness without appreciably increasing weight.

[0085] Various pads may be used with the impact liner system of the present application. The pads are generally positioned between the energy management structure and the user's head for the purpose of comfort to the wearer. However, they may also be placed between the structure and the outer shell, or between structures, and serve to alter or improve helmet performance in certain locations. The pads may be configured to deform or crush upon impact and consume a portion of the impact energy. The pads generally provide a substantially softer initial crush response than that of the energy management structure while still maintaining a nearly perfect elastic response (i.e., a full rebound or very minimal permanent deformation, depending on materials utilized). Furthermore, the pads may be configured to comfort various portions of the user's head and may be used to adjust the sizing and fit of the helmet on the user's head.

[0086] Pads of various shapes and sizes may be used. Further, the pads may be positioned and/or configured in a variety of ways to comfort various portions of the user's head. The pads may also comprise a variety of materials, such as foam (e.g., polyurethane foam, polyethylene foam, etc.), expanded polypropylene, expanded polystyrene, vinyl nitrile, or molded polymer structures such as thermoplastic urethane (TPU). The pads may be water resistant or moisture absorbent. Further, any one or more of the pads may comprise a different type of material than another pad. The pads may also be encased in a fabric and/or film material.

[0087] FIGS. 14A and 14B illustrate a pad structure 1400 attached to the top portion 704 of the energy management structure 700 illustrated in FIGS. 7A-7D. As shown, the pad structure 1400 is circular in shape and is substantially the same diameter as the top wall 706. The pad structure 1400 comprises a resilient foam 1410 encased in a collapsible, hemispherical polymer structure 1412. Further, the polymer structure 1412 comprises a central opening 1414 that permits air to escape from within the energy management structure 700 and through the porous foam 1410 during impact. Further, the opening 1414 permits air to circulate through the energy management structure 700 to facilitate cooling of the user's head. The top portion 704 of the energy management structure 700 comprises a radial projection 782 that may be used to facilitate alignment and/or attachment of the pad structure 1400 to the top portion.

[0088] FIGS. 11A-11B and 15A-15C illustrate various embodiments of collapsible polymer pad structures according to embodiments of the present application. FIG. 15A illustrates a polymer pad structure 1500 having a collapsible, hemispherical body portion 1510 with a central opening 1512 that permits air flow into and out of the energy management structure. FIG. 15B illustrates a polymer pad structure 1520 having a collapsible, hemispherical body portion 1530 with a plurality of openings 1532 for air flow. FIG. 15C illustrates a polymer pad structure 1540 having a corrugated body portion 1550 that permits the structure to collapse during an impact event. FIGS. 11A-11B illustrate a diamond shaped polymer pad structure 1100 having a collapsible body portion 1110 with a plurality of centrally located openings 1112 that permit air flow into and out of the energy management structure 1000.

[0089] The pads of the present application generally have a thickness between about 0.050 inch and about 0.5 inch. For example, in one embodiment, the thickness of the pads are about 0.125 inch. Pads of various thicknesses may also be used to adjust the sizing and fit of the helmet on the user's head.

[0090] The pads may be attached to the energy management structures in a variety of ways and may or may not be removable from the structure. For example, the pads may be attached to the energy management structures with a friction or interference fit, one or more fasteners, Velcro®, adhesive, clips, pins, snaps, tape, buckles, or the like. Further, the pads may be integrally formed with the energy management structures or separately formed and RF welded to the structure. Other methods for fabricating and assembling the pads may also be used, such as, for example, ultrasonic, heat staking, co-molding, insert molding, thermoforming, or rotomolding.

[0091] FIGS. 16A-16C illustrate attachment features 1602 and 1604 attached to the top portion 704 and the bottom portion 450 of the energy management structure 700. In certain embodiments, the attachment feature 1604 on the bottom portion 450 is used to removably attach the energy management structure, and often a corresponding carrier of the impact liner system, to the interior or backface of a helmet shell. As shown, the attachment feature 1604 is a piece of Velcro® (e.g., hook fabric or loop fabric) that is configured to mate with a corresponding piece of Velcro® (e.g., loop fabric or hook fabric) on the interior of the helmet shell to removably attach the energy management structure and generally the corresponding carrier to the helmet shell. However, a wide variety of other attachments features may be used to attach one or more of the energy management structures to the interior of the helmet shell. Examples of attachment features that may be used include, but are not limited to, one or more fasteners, adhesive, clips, pins, snaps, tape, buckles, hook and loop, or pin and slot. In certain embodiments, one or more of the energy management structures are attached to the interior of the helmet shell with the attachment feature but without being attached to a carrier of the impact liner system and/or without being connected to another energy management structure.

[0092] In certain embodiments, the attachment feature 1602 on the top portion 704 is used to removably attach one or more pads or other items to the energy management structure. As such, the pads may be configured to comfort various portions of the user's head and may be used to adjust the sizing and fit of the helmet on the user's head. Further, the pads may be positioned to alter or improve helmet performance in certain locations. As shown, the attachment feature 1602 is a piece of Velcro® (e.g., hook fabric or loop fabric) that is configured to mate with a corresponding piece of Velcro® (e.g., loop fabric or hook fabric) of the pad or other item to removably attach the pad or other item to the energy management structure. However, a wide variety of other attachments features may be used to attach one or more pads or other items to the energy management structure. Examples of attachment features that may be used include, but are not limited to, one or more fasteners, adhesive, clips, pins, snaps, tape, buckles, hook and loop, or pin and slot.

[0093] The stiffness response of the impact liner system of the present application may be modified or tuned in a variety of ways. For example, the energy management structures may be tuned to have a desired stiffness response. In certain embodiments, these structures may be tuned without regard to the comfort or wearability of the helmet due to the presence of the pads. The stiffness response of the energy management structures may be tuned in a variety of ways, such as by altering the size (e.g., diameter, height, etc.), shape (e.g., cross sectional shape), wall thickness, angle, draft, or type of material of one or more of the energy management structure components.

[0094] For example, the material and/or geometry of the energy management structures may be selected to provide various stiffness responses. As described above, the cylindrical vertical wall of the energy management structure provides an initial impact response and the vertical wall of the inner structure provides a secondary impact response. Further, the material of the energy management structure may be selected to “tune” the stiffness response. For example, a harder or softer material may be used to increase or decrease, respectively, the stiffness. Ribs may also be added to the walls of the energy management structure to increase the stiffness of the structure. The energy management structures may also be spaced or arranged to provide a desired stiffness response, e.g., rectangular, staggered, patterned, or circular arrangements.

[0095] Once the energy management structures are tuned to have a desired stiffness response, the pads may be tuned to provide a desired stiffness while still maintaining a degree of softness or comfort. For example, the type of material, density, thickness, shape, size, and configuration of the pads may be altered to provide more or less stiffness or comfort. As described above, the pads may be configured to provide an initial comfort response and the vertical walls of the energy management structure provides a secondary impact response, the secondary impact response being more stiff than the initial comfort response.

[0096] The impact liner system of the present application may also be adapted and configured in a variety of ways. For example, any one or more of the energy management structures may be removed from a carrier and replaced with a similar or different energy management structure, e.g., with an energy management structure having a different stiffness response. Further, the top portion of any one or more of the energy management structures may be removed from the base portion and replaced with a similar or different top portion. Still further, the bottom portion of any one or more of the energy management structures may be removed from the top portion and replaced with a similar or different bottom portion. In certain embodiments, the energy management structures may be configured to provide a rigid stiffness response when the threat is from high velocity impacts, such as ballistic or other high velocity impacts. In other embodiments, the energy management structures may be configured to provide a softer or less rigid stiffness response when the threat is from lower velocity impacts.

[0097] The impact liner system of the present application may also act as a ventilation system to cool the user's head. For example, as discussed above, the carriers, energy management structures, and/or pads may comprise openings or slots that permit air to circulate between the head of the user and the helmet shell to facilitate cooling of the user's head.

[0098] The words used in the claims have their full ordinary meaning and are not limited in any way by the description of the embodiments in the specification. Further, as described herein, when one or more components are described as being connected, joined, affixed, coupled, attached, or otherwise interconnected, such interconnection may be direct as between the components or may be in direct such as through the use of one or more intermediary components. Also as described herein, reference to a “member,” “component,” or “portion” shall not be limited to a single structural member, component, or element but can include an assembly of components, members or elements.

[0099] While the present invention has been illustrated by the description of embodiments thereof, and while the embodiments have been described in considerable detail, it is not the intention of the applicants to restrict or in any way limit the scope of the invention to such details. Additional advantages and modifications will readily appear to those skilled in the art. For example, component geometries, shapes, and dimensions can be modified without changing the overall role or function of the components. Therefore, the inventive concept, in its broader aspects, is not limited to the specific details, the representative device, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's general inventive concept.

[0100] While various inventive aspects, concepts and features of the inventions may be described and illustrated herein as embodied in combination in the exemplary embodiments, these various aspects, concepts and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof. Unless expressly excluded herein all such combinations and sub-combinations are intended to be within the scope of the present inventions. Still further, while various alternative embodiments as to the various aspects, concepts and features of the inventions—such as alternative materials, structures, configurations, methods, devices and components, alternatives as to form, fit and function, and so on—may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the inventive aspects, concepts or features into additional embodiments and uses within the scope of the present inventions even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present disclosure, however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated. Moreover, while various aspects, features and concepts may be expressly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts and features that are fully described herein without being expressly identified as such or as part of a specific invention, the inventions instead being set forth in the appended claims. Descriptions of exemplary methods or processes are not limited to inclusion of all steps as being required in all cases, nor is the order that the steps are presented to be construed as required or necessary unless expressly so stated.