Helmet liner

Abstract

A helmet liner adapted to be conformed to an inner surface of a helmet to cushion in use the rear of a wearers head from the helmet is described. The liner comprises a plurality of elongate grooves comprising at least one longitudinal groove configured to extend in use along a longitudinal direction between the nape of a wearers neck and the crown of the wearers head, and at least one lateral groove adapted to extend in use at least partially around the head of the wearer in a lateral direction between the wearers ears. The at least one longitudinal groove is deeper than the at least one lateral groove.

Claims

1. A helmet liner adapted to be conformed to an inner surface of a helmet to cushion in use the rear of a wearer's head from the helmet, the liner comprising a plurality of elongate grooves comprising at least one longitudinal groove configured to extend in use along a longitudinal direction between the nape of a wearer's neck and the crown of the wearer's head, and at least one lateral groove adapted to extend in use at least partially around the head of the wearer in a lateral direction between the wearer's ears; wherein the at least one longitudinal groove is deeper than the at least one lateral groove; wherein at least one of the longitudinal grooves or lateral grooves define two or more pillars, coupled together by a base adapted to lie toward the helmet so that the pillars extend in use from the base towards the head of a wearer; and wherein each pillar is tapered from the base in towards an end, carrying an end surface adapted to face the head of the wearer, and the tapering of each pillar is selected according to the curvature of the helmet so that when the base is conformed to the helmet, the end of each pillar is not pressed against another pillar, and the spacing between the two or more pillars is selected based on the curvature of the helmet and the length of the two or more pillars so that when the base is conformed to the helmet, voids remain between the two or more pillars, wherein at least one of the voids is frustum shaped.

2. The helmet liner of claim 1 wherein each pillar extends from the base so the spacing of the end surface from the base is greater than at least one of the lateral and longitudinal extent of each pillar.

3. The helmet liner of claim 1 wherein the liner is adapted to relax into a flat planar configuration.

4. The helmet liner of claim 3 further comprising: at least two wings adapted to extend in the plane of the flat planar configuration when the liner is relaxed, and to extend in use laterally around the sides of the head of a wearer towards the wearer's ears when the base is conformed to the helmet.

5. The helmet liner of claim 4 wherein the lateral extent of each wing is greater than its longitudinal extent.

6. The helmet liner of claim 1 in which the end surface of each pillar comprises recesses.

7. The helmet liner of claim 6 in which the base comprises a body portion, and at least two wings, adapted to extend laterally from the body portion in the plane of the flat planar configuration when the base is relaxed.

8. The helmet liner of claim 7 in which the base comprises at least two legs coupled to the body, wherein the legs are shorter than the wings and are adapted to extend laterally from the body in the plane of the flat planar configuration when the base is relaxed.

9. The helmet liner of claim 1 which comprises a rate-sensitive material.

10. The helmet liner of claim 9, wherein the rate-sensitive material comprises a microcellular polyurethane foam.

11. The helmet liner of claim 9, wherein the rate-sensitive material comprises a composite material comprising i) a first polymer-based material and ii) a second polymer-based material, different from i), which exhibits dilatancy in the absence of i), wherein the second polymer-based material ii) is entrapped in a matrix of the first polymer-based material i), the composite material being unfoamed or foamed, and, when unfoamed being preparable by incorporating the second polymer-based material ii) with the first polymer-based material i) prior to formation of the matrix, or, when foamed, being preparable by incorporating the second polymer-based material ii) with the first polymer-based material i) prior to foaming.

12. A kit comprising a plurality of helmet liners according to claim 3 stacked together so that the bases are parallel.

13. A helmet comprising a helmet liner according to claim 1.

14. The helmet according to claim 13 which is an American football helmet.

Description

(1) Some embodiments of the disclosure will now be discussed, by way of example only, with reference to the accompanying drawings, in which;

(2) FIG. 1A shows a plan view of a helmet liner;

(3) FIG. 1B shows an end view of the helmet liner in FIG. 1A;

(4) FIG. 1C shows a side view of the helmet liner in FIG. 1A through the lateral line A-A across the liner;

(5) FIG. 1D shows a side view of the helmet liner in FIG. 1A through a lateral line B-B across the liner;

(6) FIG. 1E shows a side view of the helmet liner in FIG. 1A across a longitudinal line C-C of the liner;

(7) FIG. 2 shows a perspective view of the helmet liner of FIG. 1A;

(8) FIG. 3A, FIG. 3B, FIG. 3C, and FIG. 3D show the helmet liner of FIG. 1A and FIG. 2 coupled to a shell in elevation, front, side and rear views.

(9) In the drawings, like reference numerals are used to indicate like elements.

(10) The inventors in the present case have identified a number of particularly useful configurations of a helmet liner.

(11) FIG. 1A shows a helmet liner adapted to protect a rear part of a wearer's head, for example a part of the head between the crown and the nape of the neck.

(12) FIG. 1A shows the liner in a relaxed configuration, in which the liner is arranged in a flat planar configuration. The helmet liner illustrated in FIG. 1A comprises a body 22 adapted to lie in a longitudinal direction spanning at least a part of the distance between the crown and the nape of the neck. As illustrated in FIG. 1A, coupled to the body 22 are two wings 10, 10 which extend laterally from each side of the body 22. The wings 10, 10 may be arranged symmetrically about a centre line C-C of the body 22.

(13) In the present disclosure the lateral direction is intended to mean the direction from the rear of the head around towards the ears. Accordingly, the liner can be conformed to the shape of a wearer's head so that the body 22 lies along a part of the head between the crown and the nape of the neck (in a longitudinal direction), and the wings 10, 10 extend in use laterally around the sides of the head toward the wearers ears.

(14) As shown in FIG. 1A, the lateral extent of each wing 10, 10 is greater than its longitudinal extent, and the wings 10, 10 may be tapered so that the longitudinal extent of each wing 10, 10 may be greater towards the tips of the wings 10, 10 (e.g. portions of the wing 10, 10 that are laterally separated from the body 22 portion).

(15) In a portion of the wings 10, 10 adjacent to the body 22, the tapering of the wings 10, 10 may be reversed. As shown in FIG. 1, a portion of the wing 10, 10 adjacent to the body 22 is greater in longitudinal extent than the rest of the wing 10, 10. The wing 10, 10 then tapers to a smaller longitudinal extent at a midriff 14, before tapering out towards the tip of the wing 10, 10.

(16) The wings 10, 10 carry, towards the tip of each wing 10, 10, a pillar 12, 12 which encloses a space corresponding to pocket 18, 18. In an alternative embodiment (not shown), pillar 12 may be replaced by at least two pillars of whose lateral extent is greater than their longitudinal extent arranged so that a lateral groove present between the at least two pillars comprises a pocket 18, 18 that is wider than the remainder of the groove. In the same alternative embodiment, one of the lateral edges of the at least two pillars carried by each wing 10, 10 may be joined together to partially enclose this pocket.

(17) As illustrated in FIG. 1A, the liner may comprise two legs 16, 16 which extend from laterally from each side of the body 22 spaced from the wings 10, 10. The legs 16, 16 may also be symmetrical about the centre line C-C of the body 22. The space between the wing 10, 10 and the leg 16, 16 may be a dog-leg 16, 16 shape that is narrower adjacent to the body 22 than towards the end of the leg 16, 16.

(18) The liner illustrated in FIG. 1A comprises a plurality of elongate grooves of varying depth which run across the surface of the liner that, in use, is to be presented towards the head of a wearer. The grooves subdivide the material of the liner into a plurality of pillars.

(19) The grooves comprise a first plurality of longitudinal grooves configured to extend in use along a longitudinal direction aligned generally in the direction between the nape of a wearer's neck and the crown of the wearer's head. The longitudinal grooves may be aligned at an acute angle to the longitudinal direction, for example they may be aligned at an angle of less than 45 to the longitudinal direction, for example they may be aligned at an angle of less than 30 to the longitudinal direction, some of the longitudinal grooves may be parallel to the longitudinal direction.

(20) The grooves comprise a second plurality of lateral grooves configured to extend in use at least partially around the head of the wearer in a lateral direction between the wearer's ears. The lateral grooves may be aligned at an acute angle to the lateral direction, for example they may be aligned at an angle of less than 45 to the lateral direction, for example they may be aligned at an angle of less than 30 to the lateral direction, some of the lateral grooves may be parallel to the lateral direction. At least one of the longitudinal grooves may be deeper than at least one of the lateral grooves.

(21) FIG. 1B shows an end view of the helmet liner shown in FIG. 1A. As can be seen in FIG. 1B, the grooves in the liner subdivide the liner into pillars, coupled together by a base. The thickness of the liner (height of the pillars plus base) is even across the majority of the liner, although the top surface of some of the pillars may be inclined with respect to the top surface of at least one adjacent pillar. The depth of the grooves defines the thickness of the base, and correspondingly may also be considered to define the height of the pillars.

(22) When the liner is conformed to a helmet, the base is adapted to lie toward the helmet so that the pillars extend in use from the base towards the head of a wearer. The pillars may be substantially trapezoidal in cross section.

(23) In an embodiment each pillar is tapered from the base in towards an end, carrying an end surface adapted to face the head of the wearer, and the tapering of the pillars may be selected according to the curvature of the helmet so that when the base is conformed to the helmet, the end of each pillar is not pressed against an adjacent pillar.

(24) FIG. 3 shows an example of a helmet liner conformed to a helmet shell. As illustrated in FIG. 3, the pillars extend from the base so the spacing of a pillar's end surface from its base is greater than at least one of the lateral and longitudinal extent of the pillar. FIG. 3 shows that the spacing between the pillars may be selected based on the curvature of the helmet shell, and the length of the pillars so that when the base is conformed to the helmet, voids remain between the pillars.

(25) Advantageously, at least one of the voids may be prism shaped and comprise at least one trapezoidal face. As a result, at least one of the voids may be frustum shaped, being open topped and broader toward its base than towards the end surface of the pillar.

(26) Referring now in more detail to the embodiment shown in FIG. 3 the helmet liner comprised a plurality of pillars, coupled together by a flexible base conformed to an inner surface of a helmet shell. As can be seen in FIG. 3, in this configuration, the base lies toward the helmet shell, and the pillars extend in use from the base towards the head of a wearer. Each pillar may be tapered from the base in towards its end. The end of each pillar may carry an end surface adapted to face the head of the wearer.

(27) The pillars can extend from the base so the spacing of their end surfaces from the base is greater than at least one of the lateral and longitudinal extent of the pillar. In the embodiment illustrated in FIG. 3, the spacing between the pillars is selected based on the curvature of the helmet and the length of the pillars so that when the base is conformed to the helmet frustum shaped voids remain between the pillars. As will be appreciated, these voids may correspond to the lateral and longitudinal grooves discussed above with reference to FIG. 1A and FIG. 1B.

(28) As illustrated in FIG. 3 when the base is conformed to the helmet, the end surfaces of the pillars may present a continuous support surface to the head of the wearer. The continuous support surface comprises at least one gap to permit air to flow from the surface into at least one of the voids between the pillars. The end surfaces of the pillars may comprise recesses.

(29) As will be appreciated by the skilled reader in the context of the present disclosure, each of the examples described herein may be implemented in a variety of different ways. Any feature of any aspects of the disclosure may be combined with any of the other aspects of the disclosure. For example method aspects may be combined with apparatus aspects, and features described with reference to the operation of particular elements of apparatus may be provided in methods which do not use those particular types of apparatus. In addition, each of the features of each of the embodiments is intended to be separable from the features which it is described in combination with, unless it is expressly stated that some other feature is essential to its operation. Each of these separable features may of course be combined with any of the other features of the embodiment in which it is described, or with any of the other features or combination of features of any of the other embodiments described herein.

(30) Aspects of the disclosure are set out in the following numbered clauses:

(31) C1. A helmet liner adapted to be conformed to an inner surface of a helmet to cushion in use the rear of a wearer's head from the helmet, the liner comprising a plurality of elongate grooves comprising at least one longitudinal groove configured to extend in use along a longitudinal direction between the nape of a wearer's neck and the crown of the wearer's head, and at least one lateral groove adapted to extend in use at least partially around the head of the wearer in a lateral direction between the wearer's ears;

(32) wherein the at least one longitudinal groove is deeper than the at least one lateral groove.

(33) C2. The helmet liner of c1 wherein the grooves define pillars, coupled together by a base adapted to lie toward the helmet so that the pillars extend in use from the base towards the head of a wearer, wherein each pillar is tapered from the base in towards an end, carrying an end surface adapted to face the head of the wearer, and the tapering of the pillars is selected according to the curvature of the helmet so that when the base is conformed to the helmet, the end of each pillar is not pressed against an adjacent pillar.

(34) C3. The helmet liner of c2 wherein the pillars extend from the base so the spacing of the end surface from the base is greater than at least one of the lateral and longitudinal extent of the pillar.

(35) C4. The helmet liner of c2 or c3 wherein the liner is adapted to relax into a flat planar configuration.

(36) C5. The helmet liner of c4 further comprising: at least two wings adapted to extend in the plane of the flat planar configuration when the liner is relaxed, and to extend in use laterally around the sides of the head of a wearer towards the wearer's ears when the base is conformed to the helmet.

(37) C6. The helmet liner of c5 wherein the lateral extent of each wing is greater than its longitudinal extent.

(38) C7. The helmet liner of c6 wherein the wings are coupled to extend laterally from a body portion, and longitudinal extent of each wing is greater towards portions of the wing that are laterally separated from the body portion.

(39) C8. The helmet liner of any of c2 to c7 in which the spacing between the pillars is selected based on the curvature of the helmet and the length of the pillars so that when the base is conformed to the helmet, voids remain between the pillars.

(40) C9. The helmet liner of c8 wherein at least one of the voids is prism shaped and comprises at least one trapezoidal face.

(41) C10. The helmet liner of c8 or c9 in which at least one of the voids is frustum shaped.

(42) C11. A helmet liner comprising a plurality of pillars, coupled together by a flexible base adapted to be conformed to an inner surface of a helmet so the base lies toward the helmet and the pillars extend in use from the base towards the head of a wearer, wherein each pillar is tapered from the base in towards an end, carrying an end surface adapted to face the head of the wearer, wherein the pillars extend from the base so the spacing of the end surface from the base is greater than at least one of the lateral and longitudinal extent of the pillar and the spacing between the pillars is selected based on the curvature of the helmet and the length of the pillars so that when the base is conformed to the helmet frustum shaped voids remain between the pillars.

(43) C12. The helmet liner of c11 wherein the voids comprise at least one longitudinal groove configured to extend in use along a longitudinal direction between the nape of a wearer's neck and the crown of the wearer's head, and at least one lateral groove adapted to extend in use at least partially around the head of the wearer in a lateral direction between the wearer's ears;

(44) wherein the at least one longitudinal groove is deeper than the at least one lateral groove.

(45) C13. The helmet liner of any of c2 to c12 in which the spacing between the pillars is selected based on the curvature of the helmet, the length of the pillars, and the area of the end surfaces so that when the base is conformed to the helmet, the end surfaces of the pillars present a continuous support surface to the head of the wearer.

(46) C14. The helmet liner of c13 in which the continuous support surface comprises at least one gap to permit air to flow from the surface into at least one of the voids between the pillars.

(47) C15. The helmet liner of any of c2 to c14 in which the end surfaces of the pillars comprise recesses.

(48) C16. The helmet liner of any of c10 to c15 in which the base is adapted to relax into a flat planar configuration.

(49) C17. The helmet liner of c15 or c16 in which the base comprises a body portion, and at least two wings, adapted to extend laterally from the body portion in the plane of the flat planar configuration when the base is relaxed.

(50) C18. The helmet liner of c17 in which the base comprises at least two legs coupled to the body, wherein the legs are shorter than the wings and are adapted to extend laterally from the body in the plane of the flat planar configuration when the base is relaxed.

(51) C19. The helmet liner of any of c1 to c18 which comprises a rate-sensitive material.

(52) C20. The helmet liner of c19, wherein the rate-sensitive material comprises a microcellular polyurethane foam.

(53) C21. The helmet liner of c19, wherein the rate-sensitive material comprises a composite material comprising i) a first polymer-based material and ii) a second polymer-based material, different from i), which exhibits dilatancy in the absence of i), wherein the second polymer-based material ii) is entrapped in a matrix of the first polymer-based material i), the composite material being unfoamed or foamed, and, when unfoamed being preparable by incorporating the second polymer-based material ii) with the first polymer-based material i) prior to formation of the matrix, or, when foamed, being preparable by incorporating the second polymer-based material ii) with the first polymer-based material i) prior to foaming.

(54) C22. A kit comprising a plurality of helmet liners according to any of c4 to c21, or any preceding clause as dependent upon c4 stacked together so that the bases are parallel.

(55) C23. A helmet comprising a helmet liner according to any of c1 to c21.

(56) C24. The helmet according to c23 which is an American football helmet.