REMOVABLE COVER FOR PROTECTIVE HELMETS

Abstract

A system for covering a helmet includes a helmet and a cover. The helmet includes a shell having a first half and a second half. The cover includes a first cover half having an outer surface and an inner surface, and a second cover half having an outer surface and an inner surface. The inner surfaces of the first and second cover halves are contoured for positioning against the respective first and second halves of the shell of the helmet.

Claims

1. A system for covering a helmet, comprising: a helmet including a shell having a first half and a second half; and a cover including: a first cover half having an outer surface and an inner surface, the inner surface contoured for positioning against the first half of the shell of the helmet; and a second cover half having an outer surface and an inner surface, the inner surface contoured for positioning against the second half of the shell of the helmet.

2. The system according to claim 1, wherein the first and second cover halves of the cover have openings defined therethrough corresponding with attachment holes and vent holes defined through the shell of the helmet.

3. The system according to claim 1, wherein each of the first and second cover halves of the cover has a pre-formed shape mimicking the shape of an outer surface of the shell of the helmet.

4. The system according to claim 1, wherein the first and second cover halves of the cover are secured to the helmet by hardware of the helmet.

5. The system according to claim 1, wherein inner surfaces of the first and second cover halves of the cover include adhesive areas for securing the first and second cover halves to the helmet.

6. The system according to claim 5, wherein the adhesive areas of each of the first and second cover halves are positioned in spaced relation relative to each other around an outer edge of the inner surface of the first and second cover halves.

7. The system according to claim 6, wherein the adhesive areas of the first and second cover halves are positioned adjacent openings defined in the first and second cover halves corresponding to vent holes defined in the shell of the helmet.

8. The system according to claim 1, wherein each of the first and second cover halves includes an outer layer of material and an inner layer of material.

9. The system according to claim 1, further comprising an adhesive strip configured for positioning over a seam defined between edges of the first and second cover halves of the cover.

10. A cover for a helmet, comprising: a first cover half having a pre-formed shape, the first cover half including an outer surface and an inner surface, the inner surface contoured for positioning against a first half of a shell of a helmet; and a second cover half having a pre-formed shape, the second cover half including an outer surface and an inner surface, the inner surface contoured for positioning against a second half of the shell of the helmet.

11. The cover according to claim 10, wherein the first and second cover halves have openings defined therethrough corresponding with attachment holes and vent holes defined through the shell of the helmet.

12. The cover according to claim 10, wherein the inner surfaces of the first and second cover halves include adhesive areas.

13. The cover according to claim 12, wherein the adhesive areas of each of the first and second cover halves are positioned in spaced relation relative to each other around an outer edge of the inner surface of the first and second cover halves.

14. The cover according to claim 13, wherein the adhesive areas of the first and second cover halves are positioned adjacent openings defined in the first and second cover halves corresponding to vent holes defined in the shell of the helmet.

15. The cover according to claim 10, wherein each of the first and second cover halves includes an outer layer of material and an inner layer of material.

16. The cover according to claim 10, further comprising an adhesive strip configured for positioning over a seam defined between edges of the first and second cover halves of the cover.

17. A method of covering a helmet, comprising: positioning a first cover half of a cover against a first half of a helmet, an inner surface of the first cover half contoured to match and lay flush against an outer surface of the first half of the helmet; and positioning a second cover half of a cover against a second half of the helmet, an inner surface of the second cover half contoured to match and lay flush against an outer surface of the second half of the helmet.

18. The method according to claim 17, further comprising: applying pressure to the first cover half after positioning the first cover half against the first half of the helmet to secure adhesive areas disposed on the inner surface of the first cover half to the outer surface of the first half of the helmet; and applying pressure to the second cover half after positioning the second cover half against the second half of the helmet to secure adhesive areas disposed on the inner surface of the second cover half to the outer surface of the second half of the helmet.

19. The method according to claim 17, further comprising: attaching hardware to the helmet to secure the first and second cover halves of the cover to the helmet.

20. The method according to claim 17, further comprising: applying an adhesive strip over a seam defined between edges of the first and second cover halves after positioning of the first and second cover halves against the first and second halves of the helmet.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The above and other aspects, features, and advantages of the present disclosure will be apparent in light of the following detailed description when taken in conjunction with the accompanying drawings, which are incorporated in and constitute a part of this specification, wherein:

[0031] FIG. 1 is an isometric view of a representative football helmet including a shell and hardware for use with a cover of the present disclosure;

[0032] FIG. 2 is an isometric view of the shell of the football helmet of FIG. 1, with the hardware removed;

[0033] FIG. 3 is an isometric view of a cover including first and second cover halves in accordance with an embodiment of the present disclosure;

[0034] FIG. 4A is a side view of an outer surface of the first cover half of the cover of FIG. 3;

[0035] FIG. 4B is a side view of an inner surface of the first cover half of the cover of FIG. 3, illustrating adhesive areas of the inner surface in accordance with an embodiment of the present disclosure;

[0036] FIG. 5A is a front view of the shell of the football helmet of FIG. 2, with the first and second cover halves of the cover of FIG. 3 positioned on the sides of the helmet prior to assembly;

[0037] FIG. 5B is a front view of the football helmet and cover of FIG. 5A, with the first and second cover halves of the cover assembled onto the shell of the football helmet;

[0038] FIG. 6A is a back view of the shell of the football helmet of FIG. 2, with the first and second cover halves of the cover of FIG. 3 positioned on the sides of the helmet prior to assembly;

[0039] FIG. 6B is a back view of the football helmet and cover of FIG. 6A, with the first and second cover halves of the cover assembled onto the shell of the football helmet;

[0040] FIG. 7 is an isometric view of the football helmet and cover of FIGS. 5B and 6B, with an adhesive strip of the cover positioned adjacent a seam of the cover prior to assembly in accordance with an embodiment of the present disclosure; and

[0041] FIG. 8 is an isometric view of the football helmet and cover of FIG. 7, with the adhesive strip assembled onto the first and second cover halves of the cover and hardware of the football helmet re-attached to the shell of the football helmet.

DETAILED DESCRIPTION

[0042] Embodiments of the present disclosure will now be described in detail with reference to the drawing figures wherein like reference numerals identify similar or identical elements. Throughout this description, the term end-user refers to the person applying a cover of the present disclosure to a helmet and thus, is not limited to the wearer of the helmet. In the following description, well-known functions or constructions are not described in detail to avoid obscuring the present disclosure in unnecessary detail.

[0043] Referring now to FIG. 1, an exemplary helmet 1 in the form of a football helmet is shown for use with a cover of the present disclosure. Any type of sports helmet may be used with one or more of the concepts described herein, a football helmet 1 is used solely for illustrative purposes. Helmet 1 generally includes a shell 2 and associated components or hardware, such as padding 4, a facemask 6, clips 7, snaps 8, trim 9, etc. The shell 2 is a hard protective housing that protects the head of a wearer. The shell 2 has an outer surface 2a that is visible to the environment and an inner surface 2b for placement over the head of the wearer. The padding 4 is disposed on the inner surface 2b of the shell 2 and may be a liner or liner system of, for example, molded foam, for added protection and to maximize impact absorption. The padding 4 may be a removable insert for a custom fit or to accommodate a fit preference of the wearer. The facemask 6 is secured to the front of the shell 2 by the clips 7 (e.g., tabs and screws) for protection of the face of the wearer. The snaps 8 are secured at pre-selected locations about the outer surface 2a of the shell 2 for attachment of additional components, such as a chin strap (not shown).

[0044] The shell 2 of the helmet 1 is shown in FIG. 2. Attachment holes 3a are defined through the shell 2 for securing the associated components, as described above, thereto. Vent holes 3b are also defined through the shell 2 for allowing air to pass through the shell 2 and into the helmet 1.

[0045] Turning now to FIG. 3, a cover 10 for use with the helmet 1 (FIG. 1) is shown. The cover 10 includes a first cover half or portion 10a and a second cover half or portion 10b. The first and second cover halves 10a, 10b are configured and dimensioned to be placed over and cover first and second halves 5a, 5b (FIG. 6A), e.g., left and right halves, of the shell 2 of the helmet 1. While the cover 10 is shown as including first and second cover halves 10a, 10b corresponding with the left and right halves of the helmet 1, it should be understood that the first and second cover halves may correspond with front and back halves of the helmet, or the cover may be formed from a single piece or more than two pieces (e.g., three pieces) dependent upon the type and/or configuration of the helmet upon which the cover is to be placed.

[0046] The first and second cover halves 10a, 10b of the cover 10 are shaped (i.e., have a pre-formed shape) to correspond with the shape of the outer surface 2a (FIG. 1) of the shell 2 of the helmet 1. The cover 10 is formed to match the contours of the outer surface 2a of the shell 2 of the helmet 1, and includes openings 11 defined therethrough that correspond with the attachment and vent holes 3a, 3b (FIG. 2) of the shell 2 of the helmet 1. Additionally or alternatively, the cover may include openings defined therethrough that provide a perforated effect different from that of the helmet (e.g., the openings in the cover corresponding with the vent holes may not be cut out or may be modified).

[0047] The cover 10 is positionable flush against the outer surface 2a of the shell 2 of the helmet 1 to present a new outer surface of the helmet 1. While the cover 10 is shown mimicking the shape of the helmet 1, it is envisioned that inner surfaces 12a, 12b of the first and second cover halves 10a, 10b may be contoured to conform to the shape of the outer surface 2a of a helmet 1 over which the cover 10 is placed, and outer surfaces 14a, 14b of the first and second cover halves 10a, 10b may have a different shape to change the appearance and/or shape of the helmet 1.

[0048] The first and second cover halves 10a, 10b are formed from material(s) rigid enough to hold the shape of the cover 10, but is not brittle, and flexible enough to be manipulated for placement over the helmet 1, but does not collapse upon itself. The sturdiness of the first and second cover halves 10a, 10b allow for very easy handling and application of the cover 10 to the helmet 1 as the first and second cover halves 10a, 10b maintain their shape during handling and do not collapse or wrinkle. Thus, an end-user may, without great skill, correctly position the cover 10 over the helmet 1.

[0049] The first and second cover halves 10a, 10b of the cover 10 are each formed from one or more layers 16 (e.g., one layer, two layers, three layers, four layers, etc.) of material that are shaped to conform to the helmet 1. The layers 16 may be formed from the same material or different materials and have the same or different thicknesses as long as the balance between rigidity and flexibility is maintained. Additionally, the overall thickness of the first and second cover halves 10a, 10b is thin to provide inherent flexibility to the cover 10. The thickness of the cover 10 may range from about 0.004 inches to about 0.03 inches. Additional protective layers may be included with the first and second cover halves depending upon a particular purpose. For example, one or more impact-absorbent materials may be provided as an additional layer.

[0050] The layer(s) 16 are mechanically formed to rigidly hold the exterior shape of the helmet 1 while being inherently flexible due to the thinness of the formed cover 10. The layer(s) 16 are formed to match the shape of the specific helmet using methods within the purview of those skilled in the art, such as a method that heats and forms a sheet of material, such as a thermoforming process. Materials which may be utilized in the thermoforming process include, for example, PE (polyethylene), PS (polystyrene), PVC (polyvinylchloride, all durometers), PP (polypropylene), PET/PETE (polyethylene terephthalate, polyester), ABS (acrylonitrile butadiene styrene), PC (polycarbonate), and urethane. Additionally or alternatively, the shape of the cover may be made by using laser mapping software or manufacturer's CAD files of the helmet to which the cover is to be applied to insure proper alignment and fit.

[0051] In embodiments in which two or more layers 16 of material are utilized to form the cover 10, the layers 16 are secured together using methods within the purview of those skilled in the art, such as a method that mechanically engages the layers 16 together, such as a laminating process. The laminating process may be achieved using any combination of adhesives, static, heat, and/or pressure.

[0052] In embodiments in which two or more layers 16 of material are utilized to form the cover 10, different materials may be selected. An advantage of using different materials is that the outer layer can be selected for its aesthetic customizability (e.g., ability to be printed) and the inner layer can be selected based on durability, strength, and ability to be formed (e.g., molded). For example, a vinyl material may be utilized as the outer layer of the cover and a sturdier plastic material may be utilized as the inner layer of the cover. As another example, an inner layer of the cover may be more rugged than an outer layer of the cover, even if it is very thin (e.g., thinner than the outer layer).

[0053] In embodiments, one of the layers 16 of the cover 10 may be a flexible circuit, or other similar electronic, that includes circuitry for determining or registering one or more pre-selected conditions. In some embodiments, the layer including the circuitry may be positioned between inner and outer layers of the cover. The pre-selected condition may include one or more of the following: pre-impact conditions (e.g., medical base of brain or brain activity, temperature, atmospheric conditions, altitude, etc.); concurrent-impact conditions (e.g., impact force (vector (x, y, and z)-forces (as it relates to or as it affects the wearer)), impact angle, impact effect on helmet, etc.); and/or post-impact conditions (e.g., helmet damage, medical condition of the wearer (e.g., knocked out or fatality), likelihood or level of concussion as it relates to impact force, brain activity, etc.). Various types of sensors or accelerometers may be embedded into the circuitry to accomplish one or more of these purposes.

[0054] Each of the first and second cover halves 10a, 10b may be finished to the correct size and configuration using methods within the purview of those skilled in the art, such as a secondary process for cutting and/or trimming the cover 10. Such processes include, for example, laser cutting, mechanical punching, electrical cutting, plasma cutting, heat laser cutting, wet jet cutting, and hand trimming. Additionally or alternatively, another secondary process, such as mechanical punching or laser cutting, may be used to cut out the openings 11 in the cover 10 to match the attachment and vent holes 3a, 3b (FIG. 2) of the helmet 1 to which the cover 10 is to be applied.

[0055] As shown in FIGS. 3 and 4A, the outer surfaces 14a, 14b of the first and second cover halves 10a, 10b of the cover 10 may be manufactured to the color, texture, and aesthetic specification requested by a consumer (e.g., direct printing and/or using printed decals) and/or standard colors (e.g., opaque, translucent, or transparent colors) or a clear cover may be manufactured for off-the-shelf purchases that can be decorated additionally with printed decals. The cover 10 may be decorated after it is formed using, for example, front or reverse printed decals, silk screening, ink jet printing, or other direct printing methods. The cover 10 may additionally or alternatively be decorated by the consumer or end-user before or after it is assembled to the helmet 1.

[0056] The cover 10 may be removably attached to the helmet 1 by chemical and/or mechanical methods. Chemical methods include, for example, the use of adhesives. The adhesive may be adhesive tape, adhesive liquids, spray adhesives, and/or static adhesives. The adhesive may be repositionable, and are not permanent adhesive. Mechanical methods include, for example, utilizing the existing hardware of the helmet to secure the cover 10 to the helmet 1.

[0057] As shown in FIGS. 3 and 4B, the inner surfaces 12a, 12b of the first and second cover halves 10a, 10b of the cover 10 include adhesive areas 18 for releasably securing the cover 10 to the helmet 1 (FIG. 2). While only the first cover half 10a is shown in FIGS. 4A and 4B, it should be understood that the second cover half 10b is substantially identical to the first cover half 10a, as seen, for example, in FIG. 3.

[0058] In embodiments, the adhesive areas 18 include manufacturer or factory applied adhesive (e.g., adhesive dots, adhesive strips, or combinations thereof). A non-stick liner (not shown) may be disposed over the adhesive areas 18 to protect the pre-applied adhesive and prevent sticking of the adhesive to other objects prior to assembly onto the helmet 1.

[0059] In embodiments, the adhesive areas 18 are defined areas on the inner surfaces 12a, 12b of the first and second cover halves 10a, 10b (e.g., marked or outlined areas) to which the end-user applies adhesive (e.g., an adhesive tape). In embodiments, instructions are provided to the end-user as to the correct placement of adhesive. In some embodiments, adhesive strips are provided that may be applied along portions of the cover corresponding with the wearer's jaw line, temple, and/or crown.

[0060] The adhesive areas 18 are strategically placed by the factory or manufacturer to the inner surfaces 12a, 12b of the first and second cover halves 10a, 10b of the cover 10 to use the fewest points of attachment and still maintain adherence so that the cover 10 does not disassemble from the helmet 1 during use. As seen in FIGS. 3 and 4B, the adhesive areas 18 are adhesive dots that are placed in spaced relation relative to each other around the outer edge of the inner surfaces 12a, 12b of the first and second cover halves 10a, 10b, and near the openings 11 corresponding with the vent holes 3b of the helmet 1. Limiting the amount of adhesive is advantageous because the cover 10 is temporarily applied and the more adhesive required, the more difficult it is for the end-user to apply and remove the cover 10 from the helmet 1.

[0061] The inner surfaces 12a, 12b of the first and second cover halves 10a, 10b, or any portion thereof, may be spray coated with a non-slip material that is repositionable as needed to assure proper alignment. These adhesives are sometimes referred to as multi-use adhesives, reusable adhesives/polymers, reversible adhesives, sticky polymers, etc. These adhesives provide high retention forces in one direction (e.g., horizontal to reduce slippage) while being easily removable/peelable in a second direction (e.g., vertical).

[0062] In a method of end-user assembly, no glues, heat, tools (except any tools necessary to remove the helmet hardware), or machines are required for the end-user to assembly the cover 10 to the helmet 1. The hardware, e.g., facemask 6, clips 7, snaps 8, trim 9, etc. (FIG. 1), is removed from the helmet 1, as shown in FIGS. 5A and 6A, leaving the outer surface 2a of the shell 2 of the helmet 1 accessible to the end-user. The outer surface 2a of the helmet 1 is then cleaned of any debris or other substances. The nonstick liners (not shown) are removed from the inner surface 12a of the first cover half 10a of the cover 10 and the first cover half 10a is aligned with and placed over the corresponding first half 5a of the shell 2 of the helmet 1. Once positioned, pressure (e.g., hand pressure) is applied to the points on the outer surface 14a of the first cover half 10a opposite where the adhesive areas 18 (FIG. 3) are located on the inner surface 12a of the first cover half 10a to secure the first cover half 10a to the shell 2 of the helmet 1. This process is repeated to apply the second cover half 10b of the cover 10 to the helmet 1, as shown in FIGS. 5B and 6B.

[0063] With the cover 10 assembled onto the helmet 1, as shown in FIGS. 5B and 6B, a seam S is defined between edges 13a, 13b of the first and second cover halves 10a, 10b of the cover 10 (e.g., where the edges meet). The edges 13a, 13b of the first and second cover halves 10a, 10b forming the seam S may line up exactly (e.g., perfectly abut), have a measurable overlap, or have a measurable gap G due to manufacturing tolerances, as shown for example, in FIG. 7.

[0064] Seams are a weak point in a design because they are points where material can lift away. For example, the edges 13a, 13b of the first and second cover halves 10a, 10b of the cover 10 are exposed and could be damaged during use of the helmet 1. The two-piece construction and design of the cover 10 is used to minimize seams in the final product. The two-piece construction results in only one seam down the center of the helmet 1.

[0065] In embodiments, the first and second cover halves 10a, 10b are mechanically joined along the edges 13a, 13b to reinforce the seam S. Various mechanical interfaces that may be used to interlock the edges include, for example, dovetail, snap-fit, tongue and groove, mating grooves, etc.

[0066] In embodiments, an adhesive tape is utilized to cover and protect the seam. As shown in FIG. 7, the adhesive tape 20 is a narrow, elongated strip of material having an adhesive surface 22 that is dimensioned to cover the seam S. The adhesive tape 20 may have a width that is at least or greater than about 0.125 inches and less than about 3 inches wide. The adhesive tape 20 may have a protective liner (not explicitly shown) to cover the adhesive surface prior to use. The adhesive tape 20 may be constructed to match or contrast in color and/or design with the outer surface 14a, 14b of the first and second cover halves 10a, 10b.

[0067] After the first and second cover halves 10a, 10b are assembled onto the helmet 1, as seen in FIG. 7, the protective liner (not shown) is removed from the adhesive tape 20 and the adhesive tape 20 is applied along the seam S, as shown in FIG. 8, to seal and protect the edges 13a, 13b (FIG. 5B) of the first and second cover halves 10a, 10b. Thereafter, the hardware can be replaced on the helmet 1 to additionally secure the cover 10 to the helmet 1.

[0068] In a method of end-user disassembly, after the helmet 1, with the attached cover 10, has been used or the cover 10 is no longer desired, the cover 10 is removed, also with any special tools, materials, or machines. The hardware, e.g., facemask 6, clips 7, snaps 8, trim 9, etc., is removed from the helmet 1. The adhesive strip 20 is then pulled off, followed by each of the first and second cover halves 10a, 10b using, e.g., the end-user's hand. The adhesive strip 20 and first and second cover halves 10a, 10b are easily removed because the adhesive on adhesive strip 20 the first and second cover halves 10a, 10b are not permanent. Any remaining remnants of adhesive that may have stuck to the outer surface 2a of the shell 2 of the helmet 1 may then be removed using, for example, the end-user's fingers, fingernails, or a piece or plastic (e.g., a credit card).

[0069] The aforedescribed materials, manufacturing procedures, and methods of assembly and use may be utilized to advertise, protect, and/or analyze other consumer areas or areas of concern, such as the transportation industry. It is envisioned that the covers described herein may be utilized to cover various parts of cars, trucks, motorcycles, trains, and planes, in a similar fashion.

[0070] It is also envisioned that the manufacturing process may be configured to mold a single cover that may be operably engaged to the helmet, or mode of transportation. Two or more molds may be placed adjacent one another and secured during the process to form a single mold that can be mechanically attached to the helmet, or mode of transportation.

[0071] The covers may be provided and/or sold as part of a kit that includes one or more sets of first and second cover halves, adhesive strips, adhesives, instructions, and/or printed decals. Moreover, the covers may be stackable for easy storage and repeated use on anniversary dates for certain events, e.g., hot pink covers for October, green covers for St. Patrick's Day, camouflage covers for Veterans day, etc.

[0072] While several embodiments of the disclosure have been shown in the drawings, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. It is to be understood, therefore, that the present disclosure is not limited to the precise embodiments described, and that various other changes and modifications may be effected by one skilled in the art without departing from the scope or spirit of the disclosure. Additionally, the elements and features shown and described in connection with certain embodiments may be combined with the elements and features of certain other embodiments without departing from the scope of the present disclosure, and that such modifications and variation are also included within the scope of the present disclosure. Therefore, the above description should not be construed as limiting, but merely as exemplifications of preferred embodiments. Thus the scope of the embodiments should be determined by the appended claims and their legal equivalents, rather than by the examples given.