A batting helmet having localized impact protection comprises a rigid shell with a padded inner core affixed therein. Localized impact protection comprises additional padding attached to the inner core, increased thickness of the rigid shell, increased stiffness of the rigid shell, and additional padding attached to the rigid shell, alone or in combination, positioned in various regions of the helmet.

The present invention is directed to a protective sports helmet including a helmet shell, a face guard and an internal padding assembly positioned within the helmet shell. The internal padding assembly includes a brow pad having first and second peripheral connection portions. The internal padding assembly also includes first and second jaw pads, each having an upper connection portion that mates with the first and second connection portions, respectively, of the brow pad. The internal padding assembly also includes a crown assembly with pad elements that include an internal separation layer that partitions the element into a first inflatable section and a section un-inflatable section. The connection portion of the jaw pads also mates with frontal pad elements of the crown assembly. The internal padding assembly further includes an occipital pad assembly that engages the helmet wearer's head below the occipital bone.

Apparatus for protecting the head of a person from an external force includes an inner shell which fits over the head of the person and an outer shell which fits over the inner shell. A plurality of bags which contain a pressurized gas are disposed between the inner shell and the outer shell. When an external force is applied to the outer shell some of the bags distribute and partially absorb the external force thereby reducing the force experienced by the person.

Helmets and methods for manufacturing a helmet are described. An example helmet includes a shell and a shock absorbing liner attached to the shell. The shock absorbing liner includes a cavity. The helmet a shock absorbing insert formed of a material different than the material of the shock absorbing liner. The cavity is configured to retain the shock absorbing insert.

An impact attenuation liner for a helmet includes an additively manufactured lattice structure configured to be disposed inside the helmet. The lattice structure includes a plurality of cells, each having a plurality of struts and nodes. The lattice structure also includes a top surface having a convex curvature corresponding to an inner surface of helmet and a bottom surface having a concave curvature configured to receive a user's head.

A sports helmet kit has a shell, attachable face guard, composite helmet liner, and fit pods to improve and customize the fit of the helmet to the wearer. The composite liner consists of a base liner and a selected group of fit elements, for example, fit pods, removably attached to the inner surface of the base liner (i.e., the surface of the base liner facing the wearer's head). The fit pods are selected from a set of fit pods having different properties, for example, different sizes, thicknesses, densities, and cross-sections. The selection of fit pods from the set may be aided by taking anatomical measurements of the wearer's head and analyzing the measurements with respect to the geometry of the helmet to produce a pressure map. The measurements may be taken by physical contact or by non-contact means. The fit pods may be selected to optimize a pressure map, and thus optimize the fit, for a given wearer of the helmet.

Embodiments are directed toward a comfort liner for a helmet. The comfort liner preferably includes a latticed structure configured to couple to the helmet. The latticed structure is preferably elastically compressible and configured to prevent rotation of the helmet relative to a wearer's head in at least one dimension.

Embodiments are directed toward a helmet liner coupler for coupling a helmet liner in a helmet. The coupler preferably includes a base and a plug. The plug preferably extends away from the base. The plug is preferably configured to engage in an interference fit with a female tubular member in the helmet. The base is preferably configured to engage the helmet liner and thereby couple the helmet liner to the helmet.

A helmet includes an outer shell, a securing mechanism (e.g., a strap and belt system) for securing the shell to a user's head, and an impact-absorbing layer (e.g., expanded polystyrene (EPS), expanded polypropylene (EPP), or other suitable material) positioned on an inner surface of the outer shell. The impact-absorbing layer includes a resilient material and has an inner surface and a plurality of holes each having a hexagonal cross-sectional shape. The hexagonal holes may extend less than all the way through the impact-absorbing layer. A section of the impact-absorbing layer can have holes with a combined cross-sectional area that is at least 50% of a cross-sectional area of the inner surface of the impact-absorbing layer. the plurality of holes can define a honeycomb structure having cell walls having cell wall thicknesses, and the plurality of holes can have major diameters that are larger than the cell wall thickness of the cell walls.

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.