SAFETY HELMET WITH INTERCHANGEABLE LAYERS
20230117538 · 2023-04-20
Inventors
Cpc classification
International classification
A42B3/32
HUMAN NECESSITIES
Abstract
A modular helmet system with a removable/detachable/interchangeable exterior shell, an inner force-absorbing layer releasably connected to the rigid exterior shell layer, and a multiple fastening devices associated with the shell which allow the shell to be interchanged/replaced/reconfigured at will. The shell as a single piece unit, or combinable components bear the fastening devices designed to enable rapid, secure interchange of the helmet system's layers, therefore allowing the helmet to be adapted for climatic, functional, and aesthetic preferences.
Claims
1. A helmet system comprising: a force-absorbing layer having a first inner surface, a first outer surface, and one or more fastening receptacles fixedly connected to the force-absorbing layer, the one or more fastening receptacles defining a through-hole at least partially through the force-absorbing layer; a rigid shell having a second inner surface and a second outer surface, and one or more fastening devices fixedly connected to the second inner surface; and at least one anchor, the at least one anchor adapted to extend into the through-hole and adapted to releasably engage with the one or more fastening devices, wherein the at least one anchor includes a first portion having a cross-sectional dimension larger than a cross-sectional dimension of the through-hole when taken along parallel cross-sectional planes, respectively.
2. The helmet system of claim 1, wherein the one or more fastening receptacles includes a recess extending from the first outer surface in a direction toward the first inner surface, the recess being sized to receive at least a portion of the one or more fastening devices.
3. The helmet system of claim 1, wherein said one or more fastening devices extends outward from said second inner surface and is sized to engage with a recess in the one or more fastening receptacles.
4. The helmet system of claim 1, wherein said one or more fastening devices further comprises a flange extending outward from said second inner surface.
5. The helmet system of claim 4, wherein the at least one anchor releasably engages the one or more fastening devices by rotation of one or more fins into interference with the flange.
6. The helmet system of claim 4, wherein said flange comprises a structural feature for releasably engaging one or more fins on the at least one anchor.
7. The helmet system of claim 6, wherein said flange comprises a flange inner diameter less than an outer diameter of the one or more fins.
8. The helmet system of claim 6, wherein the anchor includes a shaft having an outer diameter and said flange comprises a flange inner diameter greater than the outer diameter of the shaft.
9. The helmet system of claim 6, wherein said flange comprises at least one notch sized to receive the one or more fins.
10. The helmet system of claim 1, further comprising a plurality of the fastening devices, a plurality of the fastening receptacles, and a plurality of the anchors, each of the plurality of the fastening devices corresponding, respectively, to each of the plurality of anchors, and to each of the plurality of fastening receptacles.
11. The helmet system of claim 1, wherein the ancho further comprises a head having a recess adapted to facilitate operation of the at least one anchor.
12. The helmet system of claim 1, wherein the anchor is accessible from the first inner surface to facilitate releasable engagement with the one or more fastening devices.
13. The helmet system of claim 10, wherein each of the plurality of anchors and each of the plurality of fastening devices are positioned within a respective one of said plurality of fastening receptacles and upon engagement of each respective fastening device with said anchor, the anchor locks the respective fastening device thereby preventing radial separation of said rigid shell and said force-absorbing layer.
14. The helmet system of claim 1, wherein the second inner surface of the rigid shell has a shape that conforms to a shape of corresponding portions of said first outer surface of the force-absorbing layer.
15. The helmet system of claim 14, wherein the conforming shapes of the second inner surface and the first outer surface allow the one or more fastening receptacles to align respectively with the one or more fastening devices when the second inner surface receives the first outer surface.
16. The helmet system of claim 1, wherein the anchor includes a shaft adapted to extend through the through-hole.
17. The helmet system of claim 1, wherein the anchor is adapted to extend into the through-hole in a direction toward the rigid shell when the anchor is releasably engaged with the one or more fastening devices.
18. The helmet system of claim 1, wherein the anchor is adapted to extend at least partially across the through-hole.
19. The helmet system of claim 18, wherein the anchor is adapted to moveably extend at least partially across the through-hole. 20.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF THE INVENTIVE EMBODIMENTS
[0029] Known protective helmets are engineered to protect the user during the performance of a specific activity, and as a result cannot be readily adapted to changing environmental conditions or the varying preferences of the user. It remained for the present inventor to recognize that making certain components of the helmet interchangeable would provide numerous benefits, including increased performance, added user comfort, versatility, and protection. The present inventor further recognized that a helmet's adaptability could be improved through the design of specific fasteners and methods that allow the helmet's shell to be both secure and easily detachable.
[0030] As shown in
[0031] The outer shell is secured to the force-absorbing layer by one or more fastening devices 40 that are located at predefined attachment points 22 on the inner surface 28 of the shell 20, or segments 20a and 20b. Although two attachment points 22 are illustrated, multiple contact points 22 on each of segments 20a and 20b, adjacent or along shared edges 24a and 24b, are contemplated, e.g., at various intervals and stress points. As illustrated, the helmet 10 is configured as a skiing helmet, however, the invention can be formed as a protective helmet for any activity, such as, for example, cycling, football, hockey, lacrosse, motorsports, skate boarding, or construction.
The Rigid Shell
[0032] As shown in
[0033] The inner surface of the rigid shell 20 comprises a plurality of fastening devices 40 located at contact points 22, generally sets of fastening devices 40, which can be arranged along internal surfaces of the shell 20, and along or adjacent shared edges of both segments 20a and 20b. The fastening devices are designed to mate with fastener receptacles 37 associated with the force-absorbing layer 30, and which are similarly arranged as part of layer 30.
Force-Absorbing Layer
[0034] As best shown in
[0035] The force-absorbing layer 30 may be formed from any resilient, preferably moldable, shock absorbing materials such as a foamed styrene polymer, a foamed urethane polymer or other foam-like material being light in weight and having shock absorbing properties. The shock absorbing material can also include superimposed layers of shock absorbing material having different absorbing properties. Although the force-absorbing layer 30 is substantially covered by the outer shell 20, a portion 34 of it may remain exposed if safety is not compromised.
[0036] The shell 20 substantially extends about the outer surface of the force-absorbing layer 30, and the inner side of the shell 20 has the same shape as the outer surface of the force-absorbing layer 30. While the fastening devices can be constructed from suitable materials such as metals, carbon fiber composites, nylon-type materials, plastics, plastic composites, and the like, plastic or nylon-type materials provide added protection to a wearer of the helmet.
Fastening Mechanism
[0037] Referring to
Fasteners
[0038] Referring to
[0039]
[0040] The rounded/curved side with the outer radius 42 includes at least one groove 44. The surface of the groove 44 runs perpendicular to the shell, creating a shelf-like surface 46 which extends outward from the groove 44 and runs parallel to the exterior surface 26 of the shell 20. The shelf-like surface 46 is widest at the midpoint of the groove 44, and decreases in width toward either side of the groove 44. The outermost edge of the fastening device's rounded side 47 is chamfered at approximately 45 degrees. The shelf 46 is formed between the groove 44 and the outer radius 42. The shelf 46 projects outward from the bottom of the surface of the groove 44.
[0041] The outermost surface of the fastening device 40 is generally parallel to the surface 26 of the shell. The fastening device 40 in this embodiment is integrally molded to the helmet 10, but other embodiments include fastening devices which are chemically or mechanically attached. The upper surface connects to the inner surface of the shell 20. The fastening device 40 is relatively thin and has a layer-like arrangement, wherein the upper surface is followed by a first outer radius, then the groove 44, then a second outer radius, then the rounded side 47.
Fastener Receptacles
[0042]
[0043] The receptacle body 51 comprises a D-shaped aperture 54 at one end, and a rectangular cavity 55 on the underside of its opposing end. The lock ring 60 is housed in a track 58 inside the receptacle body 51, allowing it to slide from a first, “locked” position to a second, “unlocked” position. The aperture of the lock ring 60 generally aligns with the opening 54 in the receptacle body 51 when in the second position. In one embodiment, a plurality of springs 62 are arranged as to exert a force between a surface of the lock ring 60 and a partition wall 57 of the anchor body, urging them apart. The springs 62 may be held in place by a channel, or any conventional attachment method, including, for example, a protuberance, a socket, welding, brazing, and gluing. The upper inside edge of the rounded section 64 of the lock ring 60 is chamfered, as is the perimeter of the upper opening 56 of the receptacle body 51. In another embodiment, only the upper surface of the receptacle body 51 is exposed on the outer surface of the force-absorbing layer 30 (e.g., force-absorbing element), however, alternate embodiments may embed the surface of the receptacle body 51 within the force absorbing layer 30.
[0044] Referring to
[0045] Fastening devices and fastener receptacles of all embodiments are of a predetermined size as to prevent separation during the course of normal use.
Operation
[0046] Referring to
[0047] When the fastening device 40 is fully inserted in the receptacle 50, the rounded/curved side with the outer radius 42 of the lock ring 60 is aligned with the groove 44 of the fastener receptacle, enabling the springs 62 to force the lock ring back into its first, “locked” position as shown by the arrow in
[0048] Since the exterior shell 20 is removable, the wearer may easily configure the helmet 10 to the climate or interchange components for aesthetic or functional reasons. Another highly important benefit comes from the fasteners 40 being unexposed to direct impact, thereby retaining the helmet's safety characteristics. The wearer is also afforded the ability to thoroughly inspect the integrity of the force-absorbing layer 30 at any time. This can prevent him or her from unwittingly relying on a compromised helmet for impact protection.
Alternative Embodiments
[0049]
[0050] The anchor 70 in this embodiment is a quick-release type screw comprising two fins 78, a shaft 76, a tapered head 72, and a recess 74. The head of the screw 72 is substantially larger in diameter than the screw's shaft 76 and comprises an exterior surface with a recess 74 to facilitate operation, as well as an interior surface 77 that engages the bottom of the countersunk hole 82. The shaft 76 has a proximal end coupled with a distal end. One or more fins 78 project outward at the distal end of the shaft 76, in a transverse direction. The screw 70 is a single, integral piece, that when rotated by its top recess 74 (such as by using a coin, flat-head screwdriver or specialty tool) will cause the fins 78 on the distal end of the shaft to also rotate.
[0051] The fastener receptacle 80, arranged within the force-absorbing layer 30, comprises a countersunk through-hole 85, sized to receive the shaft 76 and tapered head 72 of the screw 70. The through-hole extends entirely through the force-absorbing layer 30, connecting openings 82 and 86. The through-hole diameter is slightly larger than that of the screw's shaft 76, and substantially the same diameter as the opening of its corresponding flange 92. The central axis of the through hole is aligned with the center of the corresponding fastening device's flange 92. The notches 84 formed in the through hole have dimensions just large enough to allow passage of the screw's fins 78. The notches 84 align with the notches 94 on the corresponding flange, thereby aligning the screw's fins 78 with the flange's notches 94, as well as the screw's shaft 76 with the flange's inner diameter 95. Because the relatively rigid components 20 and 30 closely conform in shape, and the fastening device 90 and receptacle 80 are attached to these components respectively, the notches 84 and 94 will naturally align themselves during use. The wider segment of the countersunk hole 82 is shaped to receive the interior surface 77 of the screw's head 72. On the outer surface of the force-absorbing layer 30, an annular recess 86 is formed. The recess allows the flange 92, and thus the outer shell 20 to lie flush against the force-absorbing layer 30. In alternate embodiments of the present invention, the anchoring system may comprise any conventional releasable fastener such as a turnlock fastener, threaded screws, bolts, rib fasteners, spring clips, and the like.
[0052] A fastening device 90 is integrally formed at each attachment point 22 on the rigid shell 20. Each fastening device 90 comprises a circular flange 92 projecting inward, toward the cavity of the helmet 10. The flange 92 has an inward lip 95 with an inner diameter slightly larger than that of corresponding screw's shaft 76, creating a locking ledge 97 for the screw's fins 78. This lip forms a cylindrical cavity 96 between the flange's lip and the rigid shell, the cavity's height being approximately the height of the screw's fins 78. Since the diameter of the flange's lip 95 is too small to receive the fins 78 of the screw, the fins 78 may only enter cavity 96 by way of notches 94
Alternative Embodiments—Operation
[0053] Referring to
[0054] In the locked position, components 70, 80, and 90 are temporarily fastened. The fins 78 of the screw prevent its release from the fastening device, as the fins are of a wider diameter than the locking ledge 97 holding it in place. Additionally, the interior surface 77 of the screw's head 72 exerts a compressive force on the bottom of the receptacle's countersunk hole 82, forcing the receptacle against the fastening device. As the fastening device 90 is attached to the helmet shell 20, and the receptacle 80 is attached to the force-absorbing layer 30, the dynamics of the screw lock these two layers together. The installation of the screw can be undone by reversing the process. Turning the screw in the counterclockwise direction until the screw's fins 78 align with the flange's notches 94, and then pulling the shaft 76 of the screw out of the cavity 96 and through the receptacle's through hole 85, will allow the screw to be removed, and the layers of the helmet 10 to separate. Other embodiments of this screw and anchor design may vary in their specific design of the securement method, but are still within the scope of the invention.
[0055] The structure described above, of internally-accessible, user-operated fasteners which secure the helmet's layers produces distinct advantages over previous attempts in helmet design. Other attempts have relied upon externally-exposed fasteners with deformable materials as the primary fastening mechanism, often requiring additional features for security. These attempts are of detriment to aesthetics, as the fastening mechanisms are visible during use, to security, as the fasteners are exposed on the helmet's exterior and do not accommodate deformation during impact, and to efficiency, since the user must forcibly bend the structure to operate the fasteners. The current invention solves all of these issues, and provides an engineered design to overcome the previously intractable problem of designing an interchangeable helmet which is safe, efficient, and aesthetically appealing.
[0056] The foregoing merely illustrates the principles of the invention. For example, although the outer shell of the illustrative embodiment comprises two simple pieces, other shapes, configurations, numbers of segments, ventilation patterns, and anchoring systems are possible. It will thus be appreciated that those skilled in the art will be able to devise numerous alternative arrangements that, while not shown or described herein, embody the principles of the invention and thus are within its spirit and scope. The inventive subject matter, therefore, is not to be restricted except in the spirit of the disclosure. Moreover, in interpreting the disclosure, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced.