The invention relates to a multi-step method with a number of processes and sub-processes that interact to allow for the selection, design and/or manufacture of a protective sports helmet for a specific player, or a recreational sports helmet for a specific person wearing the helmet. Once the desired protective sports helmet or recreational sports helmet is selected, information is collected from the individual player or wearer regarding the shape of his/her head and information about the impacts he/she has received while participating in the sport or activity. The collected information is processed to develop a bespoke energy attenuation assembly for use in the protective helmet. The energy attenuation assembly includes at least one energy attenuation member with a unique structural makeup and/or chemical composition. The energy attenuation assembly is purposely engineered to improve comfort and fit, as well as how the helmet responds when an impact or series of impacts are received by the helmet.

Helmet padding systems are disclosed. One helmet padding system includes a rigid shell and a spacing pad. The rigid shell is configured to cover a top of a user's head and be worn under a piece of headgear. The rigid shell includes a pair of slots extending in a direction from a lower rear edge of the rigid shell toward a lower front edge of the rigid shell. The pair of slots define a central portion and opposed side portions of the rigid shell. The central portion includes at least one pair of flaps, with each of the at least one pair of flaps extending outwardly from the central portion into a respective slot. The central portion further includes a tail extending outwardly from the central portion into each of the slots. The spacing pad is positioned within the rigid shell. The spacing pad includes a layer of elastomeric material.

A protective helmet includes an energy dissipative assembly including a conforming protective base adapted to directly contact and conform to a corresponding bony anatomical region of a wearer's head. A supported flexible suspended crown adapted to be affixed to the conforming protective base and configured to define a gap separating substantially all of the interior surface of the supported flexible suspended crown from contact with a corresponding anatomical crown region of the wearer when the helmet is donned by the wearer. The supported flexible suspended crown including at least one contoured flexible shell or a plurality of cantilevered members comprising a compliant energy dissipating material that, when impacted, undergoes deformation to an extent that is greater than deformation, when impacted, of the deformation resistant material of the conforming protective base. An uncoupled cantilevered posterior cranial shield system includes a yoke configured to attach to or be integrated with shoulder pads or another garment and an attenuating cantilevered arch attached to the yoke at first and second emplacements, the attenuating cantilevered arch being configured to extend over a head of an individual wearing the shoulder pads or garment.

An energy absorption system is provided with a plurality of energy absorbing panels that may be releasably connected to a helmet. The energy absorbing panels are provided with a plurality of air flow channels defining a plurality of energy absorption chambers. Each of the air flow channels is designed to direct air flow from an anterior of the helmet to a posterior of the helmet when the energy absorbing panels are connected to an outer shell of the helmet.

A protective helmet includes an energy dissipative assembly including a conforming protective base adapted to directly contact and conform to a corresponding bony anatomical region of a wearer's head. A supported flexible suspended crown adapted to be affixed to the conforming protective base and configured to define a gap separating substantially all of the interior surface of the supported flexible suspended crown from contact with a corresponding anatomical crown region of the wearer when the helmet is donned by the wearer. The supported flexible suspended crown including at least one contoured flexible shell or a plurality of cantilevered members comprising a compliant energy dissipating material that, when impacted, undergoes deformation to an extent that is greater than deformation, when impacted, of the deformation resistant material of the conforming protective base. An uncoupled cantilevered posterior cranial shield system includes a yoke configured to attach to or be integrated with shoulder pads or another garment and an attenuating cantilevered arch attached to the yoke at first and second emplacements, the attenuating cantilevered arch being configured to extend over a head of an individual wearing the shoulder pads or garment.

A helmet includes a shell having an interior surface, a padding disposed along the interior surface of the shell, and a chinbar. The padding defines a first engagement surface positioned at a first lateral side of the padding and a second engagement surface positioned at an opposing second lateral side of the padding. The chinbar includes a cage, a first flange, and a second flange. The cage includes a first end defining a third engagement surface and a second end defining a fourth engagement surface. The third engagement surface interfaces with the first engagement surface and the fourth engagement surface interfaces with the second engagement surface. The first flange extends from the first end of the cage. The second flange extends from the second end of the cage. The first flange and the second flange of the chinbar are embedded within the padding.

The invention relates to a multi-step method with a number of processes and sub-processes that interact to allow for the selection, design and/or manufacture of a protective sports helmet for a specific player, or a recreational sports helmet for a specific person wearing the helmet. Once the desired protective sports helmet or recreational sports helmet is selected, information is collected from the individual player or wearer regarding the shape of his/her head and information about the impacts he/she has received while participating in the sport or activity. The collected information is processed to develop a bespoke energy attenuation assembly for use in the protective helmet. The energy attenuation assembly includes at least one energy attenuation member with a unique structural makeup and/or chemical composition. The energy attenuation assembly is purposely engineered to improve comfort and fit, as well as how the helmet responds when an impact or series of impacts are received by the helmet.

A helmet includes a shell having an interior surface, a padding disposed along the interior surface of the shell, and a chinbar. The padding defines a first engagement surface positioned at a first lateral side of the padding and a second engagement surface positioned at an opposing second lateral side of the padding. The chinbar includes a cage, a first flange, and a second flange. The cage includes a first end defining a third engagement surface and a second end defining a fourth engagement surface. The third engagement surface interfaces with the first engagement surface and the fourth engagement surface interfaces with the second engagement surface. The first flange extends from the first end of the cage. The second flange extends from the second end of the cage. The first flange and the second flange of the chinbar are embedded within the padding.

A helmet is provided that can include a body defining a front end, a rear end opposite the front end, a first lateral end and a second lateral end opposite the first lateral end. The body further defines one or more vents extending therethrough. The helmet also includes a structure at least partially embedded in the body and encircling at least one vent of the one or more vents, and a strap hanger coupled to the structure.

A protective helmet includes an energy dissipative assembly including a conforming protective base adapted to directly contact and conform to a corresponding bony anatomical region of a wearer's head. A supported flexible suspended crown adapted to be affixed to the conforming protective base and configured to define a gap separating substantially all of the interior surface of the supported flexible suspended crown from contact with a corresponding anatomical crown region of the wearer when the helmet is donned by the wearer. The supported flexible suspended crown including at least one contoured flexible shell or a plurality of cantilevered members comprising a compliant energy dissipating material that, when impacted, undergoes deformation to an extent that is greater than deformation, when impacted, of the deformation resistant material of the conforming protective base. An uncoupled cantilevered posterior cranial shield system includes a yoke configured to attach to or be integrated with shoulder pads or another garment and an attenuating cantilevered arch attached to the yoke at first and second emplacements, the attenuating cantilevered arch being configured to extend over a head of an individual wearing the shoulder pads or garment.