Protective helmet

Abstract

A protective helmet comprising a helmet shell having at least two layers and the helmet shell having a flexural modulus from 50 MPa to 600 MPa as measured using ASTM D 790 B and a non-foamed specific gravity in the range of 0.916 g/cm.sup.3 up to 1.60 g/cm.sup.3. More than one helmet shell may be combined to provide greater protection to the wearer. The layers may be constructed of an open cell foam, a waterproof coating layer, a separator layer, a flexible layer, a slightly foamed layer, and a cushion layer. A protective facial barrier may be easily removed with use of a locking mechanism which removably secures the facial barrier to the helmet shell. The helmet shells may also be in parts and hinged so that the parts can separate for easy removal of the protective helmet. An adjustment locking mechanism may also tighten and adjust a second helmet shell.

Claims

1. A protective helmet comprising a helmet shell having at least two layers and one of the at least two layers of the helmet shell having a flexural modulus from 50 MPa to 600 MPa as measured using ASTM D 790 B and a non-foamed specific gravity in a range of 0.916 g/cm.sup.3 up to 1.60 g/cm.sup.3.

2. The protective helmet of claim 1 wherein each of the at least two layers is constructed of a material selected from the group consisting of polystyrene, polypropylene, polyethylene, thermoplastic polyurethane, thermoplastic elastomers, thermoplastic polymer, vulcanized polymer, silicone polymers, EPDM polymers, natural rubber, neoprene, polyurethane foam, and polyurethane.

3. The protective helmet of claim 2 wherein the material in each of the at least two layers is crosslinked with materials selected from the group consisting of a low density polyethylene foam, a polyurethane foam, and an ethylene-vinyl acetate copolymer.

4. The protective helmet of claim 1 wherein the at least two layers are comprised of materials selected from the group consisting of a slightly foamed layer, a cushion layer, a waterproof coating layer, a flexible layer, and a separator layer.

5. The protective helmet of claim 1 wherein the at least two layers is comprised of an open cell foam.

6. The protective helmet of claim 1 wherein one of the at least two layers is a cushion layer comprised of multiple elongated foam shapes.

7. The protective helmet of claim 1 wherein one of the at least two layers is a cushion layer having a thickness in a range from 0.032 inches to 1.25 inches.

8. The protective helmet of claim 1 wherein one of the at least two layers is a waterproof coating layer comprised of a thermoplastic film adhered to a cushion layer.

9. The protective helmet of claim 1 wherein one of the at least two layers is a separator layer containing air spaces or channels throughout the separator layer.

10. The protective helmet of claim 1 wherein one of the at least two layers is a flexible layer and further comprising rigid particles adhered to the flexible layer and raised above the surface of the flexible layer.

11. The protective helmet of claim 1 wherein the helmet shell has an external side and an internal side, and further comprising removable and repositionable cushion layers pads attached to the internal side of the helmet shell.

12. The protective helmet of claim 1 wherein the helmet shell is configured to enclose all sides of a head of a wearer except the face and further comprising a protective barrier attached to the helmet shell and covering the face.

13. A protective helmet comprising a helmet shell having at least two layers and one of the at least two lavers of the helmet shell having a flexural modulus from 50 MPa to 600 MPa as measured using ASTM D 790 B and a non-foamed specific gravity in a range of 0.916 g/cm.sup.3 up to 1.60 g/cm.sup.3, the protective helmet being configured to enclose all sides of a head of a wearer except the face and further comprising a protective barrier attached to the helmet shell and covering the face, and the protective helmet further comprising at least one locking mechanism, the locking mechanism comprising an extended flexible component or latch attached to the protective barrier, the extended flexible component or latch configured to slide into a fixture assembly attached to the helmet shell and engage a hook within the fixture assembly, and a button in the fixture assembly in contact with the extended flexible component or latch for moving the extended flexible component or latch away from the hook to permit the protective barrier to move away from the helmet shell.

14. A protective helmet comprising a helmet shell having at least two layers and one of the at least two layers of the helmet shell having a flexural modulus from 50 MPa to 600 MPa as measured using ASTM D 790 B and a non-foamed specific gravity in a range of 0.916 g/cm.sup.3 up to 1.60 g/cm.sup.3, the protective helmet being configured to enclose all sides of a head of a wearer except the face and further comprising a protective barrier attached to the helmet shell and covering the face, and the protective helmet further comprising at least one locking mechanism, the locking mechanism comprising an extended flexible component or latch attached to the protective barrier, the extended flexible component or latch configured to slide into a fixture assembly attached to the helmet shell and engage a hook within the fixture assembly, and a button in the fixture assembly in contact with the extended flexible component or latch for moving the extended flexible component or latch away from the hook to permit the protective barrier to move away from the helmet shell and the protective helmet further comprising a hinge or flexible component attached to the protective barrier and the helmet shell whereby the protective barrier is capable of being rotated upward away from the face of the wearer.

15. The protective helmet of claim 1 wherein the helmet shell further comprises a front section and the rear section, the front section being connected to the rear section with a hinge whereby the front section of the helmet shell is capable of being rotated upward and away from the rear section.

16. The protective helmet of claim 1 wherein one of the at least two layers is a cushion layer with a IFD/ILD of 20 pounds to 200 lbs. as measured by ASTM D3574.

17. The protective helmet of claim 1 wherein one of the at least two layers is a cushion layer with a IFD/ILD of 60 lbs. to 70 lbs. as measured by ASTM D3574.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows a partial cross-sectional view of a single helmet shell taken at line I in FIG. 23.

(2) FIG. 2 shows a partial cross-sectional view of a helmet shell taken at line I of FIG. 23.

(3) FIG. 3 shows a partial cross-sectional view taken at line I in FIG. 23 of an alternate embodiment of a helmet shell.

(4) FIG. 3A shows a side elevational view of an embodiment of a helmet shell with elongated square or rectangular cushion layer segments.

(5) FIG. 3B shows a bottom plan view of an embodiment of a helmet shell with elongated square or rectangular cushion layer segments.

(6) FIG. 3C shows a side elevational view of an embodiment of a helmet shell with elongated cylindrical cushion layer segments.

(7) FIG. 3D shows a bottom plan view of an embodiment of a helmet shell with elongated cylindrical cushion layer segments.

(8) FIG. 4 shows a partial cross-sectional view taken at line I in FIG. 23 of an alternate embodiment of a helmet shell.

(9) FIG. 5 shows a partial cross-sectional view taken at line I in FIG. 23 of an alternate embodiment of a helmet shell.

(10) FIG. 6 shows a partial cross-sectional view taken at line I in FIG. 23 of an alternate embodiment of a of an external helmet shell.

(11) FIG. 7 shows a partial cross-sectional view taken at line I in FIG. 23 of an alternate embodiment of an external helmet shell.

(12) FIG. 8 shows a partial cross-sectional view taken at line I in FIG. 23 of an alternate embodiment of an external helmet shell.

(13) FIG. 9 shows a partial cross-sectional view taken at line I in FIG. 23 of an alternate embodiment of an external helmet shell.

(14) FIG. 10 shows a partial cross-sectional view taken at line I in FIG. 23 of an alternate embodiment of an external helmet shell.

(15) FIG. 11 shows a partial cross-sectional view taken at line I in FIG. 23 of an alternate embodiment of an external helmet shell.

(16) FIG. 12 shows a top plan view of a helmet shell with rigid particles.

(17) FIG. 13 shows a top plan view of an alternate embodiment of a helmet shell with rigid particles.

(18) FIG. 14 shows a cross-sectional view taken at line II of FIG. 39 of a helmet shell when struck by and impact force.

(19) FIG. 15 shows a cross-sectional view taken at line II of FIG. 39 of a helmet shell when struck by an impact force.

(20) FIG. 16 shows a cross-sectional view taken at line II of FIG. 39 of a helmet shell when struck by an impact force.

(21) FIG. 17 shows a cross-sectional view taken at line II of FIG. 39 of a helmet shell when struck by an impact force.

(22) FIG. 18 shows a side elevational view of a locking mechanism with protective barrier detached.

(23) FIG. 19 shows a side elevational view of a locking mechanism with protective barrier attached.

(24) FIG. 20 shows a top plan view of a locking mechanism with protective barrier detached.

(25) FIG. 21 shows a top plan view of a locking mechanism with protective barrier attached.

(26) FIG. 22 shows a front side elevational view of a protective helmet.

(27) FIG. 23 shows a left side elevational view of a protective helmet.

(28) FIG. 24 shows a cross sectional view taken at line III of FIG. 23 of a helmet shell before being struck by an impact force.

(29) FIG. 25 shows a cross sectional view taken at line III of FIG. 23 of a helmet shell after being struck by an impact force.

(30) FIG. 26 shows a side elevational view of a protective helmet with protective barrier positioned in front of wearer's face.

(31) FIG. 27 shows a side elevational view of a protective helmet with protective barrier rotated upwards.

(32) FIG. 28 shows a side elevational view of an alternate embodiment of a protective helmet in a closed position.

(33) FIG. 29 shows a side elevational view of an alternate embodiment of a protective helmet 21 in an open position.

(34) FIG. 30 shows a top plan view of an alternate embodiment of a protective helmet in a closed position.

(35) FIG. 31 shows a side elevational view of an alternate embodiment of a protective helmet in a closed position.

(36) FIG. 32 shows a side elevational view of an alternate embodiment of a protective helmet in an open position.

(37) FIG. 33 shows a cross sectional view taken at line IV of FIG. 40 of a helmet shell with an adjustment locking mechanism in an open position.

(38) FIG. 34 shows a cross sectional view taken at line IV of FIG. 40 of a helmet shell with an adjustment locking mechanism in a closed position.

(39) FIG. 35A shows a top plan view of an adjustment locking mechanism on a flexible layer of a second helmet shell with intermeshing notches in the open position.

(40) FIG. 35B shows a side elevational view of an adjustment locking mechanism in the open position.

(41) FIG. 36A shows a top plan view of an adjustment locking mechanism on a flexible layer of a second helmet shell with intermeshing notches in the closed position.

(42) FIG. 36B shows a side elevational view of an adjustment locking mechanism in the closed position.

(43) FIG. 37 shows a side elevational view of an alternate embodiment of an adjustment locking mechanism with adjustable thread screw in the open position.

(44) FIG. 38 shows a side elevational view of an alternate embodiment of an adjustment locking mechanism with adjustable thread screw in the closed position.

(45) FIG. 39 shows a top plan view of a protective helmet.

(46) FIG. 40 shows a rear elevational view of a protective helmet incorporating an adjustment locking mechanism.

DETAILED DESCRIPTION OF THE INVENTION

(47) The aspects of the Protective Helmet 21 are suitable for contact, semi-contact, limited-contact or non-contact activities, and may be used by all individuals taking part in activities, but are not limited to football, lacrosse, ice hockey field hockey, rugby, soccer, mixed martial arts, basketball, squash, racquetball, water polo, handball, wrestling, and boxing. In addition, it can be worn by individuals that have balance and medical problems that make them susceptible to falling.

(48) Unlike current helmets, the design of the protective helmet 21 disclosed in this patent application has a flexible outer structure referred to as the helmet shell 9 so when struck with an impact force, the helmet shell 9 flexes and spreads the energy of the impact force over a larger area to reduce the pounds per square inch of the force to dissipate and mitigate the energy to the wearer's head to reduce the adverse effect of an impact force. According to one aspect, the protective helmet 21, has a flexible layer helmet shell 9 comprised of a slightly foamed layer 1 having a Flexural Modulus ranging from 50 MPa to 600 Mpa as measured using ASTM D 790 B.

(49) According to one aspect of the invention, a Protective Helmet 21 includes an external head-protecting helmet shell 9 comprising a thermoplastic polymer that may or may not be crosslinked or a vulcanized polymer and these materials having a non-foam specific gravity of 916 kg/m.sup.3 up to 1600 kg/m.sup.3 ASTM D 792 with an initial Flexural Modulus above 600 Mpa as measured using ASTM D 790 B. However, the materials may be foamed to reduce its flexural modulus below 600 Mpa and to reduce it specific gravity. Foaming also reduces material cost and weight of the protective helmet 21 and make it more comfortable to the wearer. Foaming also reduces the cycle time of making the helmet shell 9 if the material is injection molded. For some materials, the shell may be below 600 Mpa in a non-foamed state, and the non-foamed material of the shell has a Flexural Modulus from 50 Mpa to 600 Mpa as measured using ASTM D 790 B. The art of extruding thermoplastics foams is well known and is described in the following U.S. patents by Knaus: U.S. Pat. No. 4,308,352 Process of Extruding Polysulfone Foam, U.S. Pat. No. 4,836,814 Multicolored foam and method for making, U.S. Pat. No. 5,589,519 Process of extruding lightly crosslinked polyolefin foam, U.S. Pat. No. 5,750,584 Stability control agent composition for polyolefin foam, or U.S. Pat. No. 5,605,937 Moldable thermoplastic polymer foam bead.

(50) Foaming a plastic has several advantages. It reduces the amount of plastic needed to produce the same volume required for a product. For example, if 1.0 pound (lbs.) of plastic is used to make a product, and the plastic is foamed to a specific gravity that is 20% lower than the non-foamed plastic specific gravity, then 20% less plastic is needed to make the same product. Thus, the cost of the product is reduced by about 20%, resulting in a substantial savings of the plastic costs. Also, the volume of material produced is increased by 20%. In addition, a foamed plastic shell is lighter in weight making it more comfortable for the wearer. If an injection molding process is used to make a shell, foaming the plastic reduces its viscosity, which makes it easier for the plastic to flow into the mold and fill the mold quicker. Thus, the molding cycle time is reduced for a foamed plastic versus the same non-foamed plastic. Foaming a plastic can also reduce its Flexural Modulus. These benefits exist for essentially all thermoplastics that can be foamed.

(51) The helmet shell 9 can be made as a single piece or multiple pieces to form a single contiguous helmet shell 9 layer. The protective helmet 21 further includes an inner cushion layer 2, typically foam, which may or may not be attached to the helmet shell 9 and has a IFD/ILD of 20 pounds to 200 lbs. and preferably 60 lbs. to 70 lbs. Preferably, the cushion layer 2 thickness can range from 0.060 inches (in.) to 1.25 inches (in.). The waterproof coating layer 3 in this patent application can be a thermoplastic film or coating adhered to the cushion layer 2. One purpose of the waterproof coating layer 3, but not the only one, is to make it water or moisture resistant and easy to clean and prevent contamination of the internal surfaces of the cushion layer 2. All components of the protective helmet 21 can contain additives such as color, an antibacterial or antifungal compound and/or a scent compound.

(52) The helmet shell 9 may be made of a one piece in some embodiments. For example, material may be made into a single piece to form the helmet shell 9, and components may be attached to the protective helmet 21 or helmet shell 9. Components such as connectors may be included on the protective helmet 21 or helmet shell 9 would still be considered one piece. In another embodiment, the helmet shell 9 may be made of more than one piece.

(53) Cushion layer 2 may be a foamed polymer such as flexible polyurethane foam. One method to make a flexible polyurethane foam is by the reaction of diisocyanates or polyisocyanates, with a polyol in the presence of a blowing agent, a surfactant, and a catalyst with or without external heating during its foaming. Cushion layer 2 may be comprised of a polystyrene, polypropylene, polyethylene, thermoplastic polyurethane (TPU), thermoplastic elastomers (TPE), Silicone polymer, EPDM polymers, Natural Rubber, Neoprene, or other suitable thermoplastics that can be crosslinked, or non-crosslinked, and foamed with a chemical or physical blowing agent.

(54) According to another aspect of this patent application, a protective helmet 21, may include an external head-protecting helmet shell 9 with an inner cushion layer 2 and a second helmet shell 9 and a second inner cushion layer 2. The helmet shell 9 may be made of a flexible thermoplastic polymer that may or may not be crosslinked or a vulcanized polymer and these materials or a combination thereof, having a non-foamed specific gravity 0.916 g/cm.sup.3 up to 1.60 g/cm.sup.3 or a density of 916 kg/m.sup.3 up to 1600 kg/m.sup.3 with a Flexural Modulus ranging from 50 Mpa to 600 Mpa as measured using ASTM D 790 B. The external helmet shell 9 and second internal helmet shell 9, can be comprised of a single piece or multiple pieces that form a single contiguous helmet shell 9 layer for either helmet shell 9. The external helmet shell 9 and second helmet shell 9 can be made of a non-foamed or foamed materials, for example, thermoplastic elastomers or a polyester elastomer such as Dupont Hytrel 4556 (94 Mpa) and Hytrel 5526 (207 Mpa).

(55) According to another aspect, a protective helmet 21 may include an external head-protecting helmet shell 9 that covers, at least partially, a wearer's head. The protective helmet 21 can also include a portion to protect the wearer's face and eyes by covering it in part or whole with a protective barrier 8 attached to the helmet shell 9. The protective barrier may be made of bars of steel rods crisscrossing in a configuration referred to as a facemask to prevent the entry of a ball, puck, stick, a hand/finger, or other objects that could injure the helmet wearer. Protective barrier 8 may also be constructed of a clear thermoplastic polymer such as polycarbonate or polysulfone, to name a few. The protective barrier 8 can be made up of a combination of a facemask and a clear thermoplastic polymer shield. In some embodiments, the protective helmet 21 includes a chin strap to enable improved adjustment and fit and to secure the protective helmet 21 to the wearer's head.

(56) In another aspect of this patent application, since heads vary in size and shape, additional cushion layer pads 32 may be provided as fillers to improve the helmet shell 9 fit. The cushion layer pads 32 can be provided with an adhesive surface or Velcro adhere to the surfaces that need the cushion layer pads 32. The cushion layer pads 32 can be interchanged and positioned by the wearer to achieve the best fit and comfort. While Velcro is described as an attachment mechanism, other methods such as adhesives or magnets or magnetic materials, can be used.

(57) As shown in FIG. 1 and FIGS. 22 and 23, protective helmet 21 may be comprised of an external helmet shell 9 which may be comprised of a slightly foamed layer 1 and a cushion layer 2 that provides protection to the wearer's head in some embodiments. Each helmet shell 9 should be configured to enclose the head of a wearer, each helmet shell having an external side facing away from the head and an internal side facing toward the head of the wearer. Slightly foamed layer 1 may be constructed of a thermoplastic polymer that may or may not be crosslinked or a vulcanized polymer and had a flexural modulus above 600 Mpa before it was slightly foamed and after it is slightly foamed has a flexural modulus ranging from 50 Mpa to 600 Mpa. FIG. 1 shows a partial cross-section of a single helmet shell 9 taken at line I in FIG. 23 with slightly foamed layer 1 material and a cushion layer 2 depicted. Helmet shell 9 has a reduced specific gravity achieved by foaming it and has a Flexural Modulus ranging from 50 Mpa to 600 Mpa as measured using ASTM D 790 B. It should be appreciated that aesthetic additions to the protective helmet 21 which do not provide protection to the wearer's head, such as paint, decals, or stickers, may be applied to the outer surface of the protective helmet 21, and the external helmet shell 9 still be considered the outermost layer of the helmet.

(58) In some embodiments, the cushioning material of the external helmet shell 9 has a IFD/ILD of 60 lbs. to 70 lbs and with the helmet shell 9 having a flexural modulus ranging from 50 Mpa to 600 Mpa as measured using ASTM D 790 B. In some embodiments, the external helmet shell 9 is made of a thermoplastic polymer having a specific gravity less than its non-foamed state. The thermoplastic polymer may be thermoplastic elastomer (TPE), thermoplastic polyurethane (TPU), or any other suitable thermoplastic polymer. The specific gravity of the foamed thermoplastic polymer may be 10% to 99% of the non-foamed counterpart. For example, if the non-foamed polymer has a specific gravity of 1.0, then the foamed polymer may have a specific gravity in the range of 0.10 to 0.99. The external helmet shell 9 may have a thickness range of 0.050 inches to 1.25 inches, or any other suitable thickness based on the application and intended use.

(59) As seen in FIG. 1 through FIG. 11, each layer of the helmet shell 9 may be attached to each other by any suitable arrangement, such as glue, hot melt glue, Velcro or any suitable method well known in the art. As used herein, the term attached includes, but is not limited to, arrangements in which items are directly attached to one another. Additionally, a first item can be considered to be attached to a second item by being attached to the second item via an intermediate component or components. Different types of cushion layer 2 may be attached to the inside of the helmet shell 9. In all embodiments, the cushion layer 2 may be more flexible than the external head-protecting shell.

(60) The cushion layer 2 may have a thickness of 0.032 inches to 1.25 inches. In some embodiments, the cushion layer 2 may have a thickness range from 0.05 inches to 0.500 inches. In most embodiments the thickness of the cushion layer 2 will be maximized in most or all areas of the helmet shell 9 to provide the helmet wearer with the maximum protection against the effects of the energy from an impact force.

(61) In all embodiments, the cushion layer 2 is made of a foam, such as foamed thermoplastic polymer with or without ethylene vinyl acetate copolymer as a softener, that can be crosslinked, non-crosslinked, or a flexible polyurethane foam prepared by the reaction of a diisocyanates or polyisocyanates with a polyol in the presence of a blowing agent, a surfactant, and a catalyst with or without external heating during its foaming, or a polyurethane thermoplastic made with a chemical or physical blowing agent or a vulcanized polymer that is foamed. The foam may be compression molded, die cut, or processed by any other suitable method.

(62) In some embodiments, the helmet shell 9 includes areas of a cushion layer 2 that is thinner. In some embodiments, a secondary cushion layer 2 may be thinner. In one embodiment, the secondary cushion layer 2 thickness is at least the same as the first cushion layer 2 or thicker.

(63) In another embodiment, FIG. 2, shows a partial cross-section of helmet shell 9, taken at line I of FIG. 23, comprised of a slightly foamed layer 1, made from a thermoplastic polymer that may or may not be crosslinked or a vulcanized polymer and had a Flexural Modulus above 600 MPa before it was slightly foamed and after it is slightly foamed has a Flexural Modulus ranging from 50 MPa to 600 MPa. The cushion layer 2 can be made from a foamed thermoplastic polymer that can be crosslinked, or non-crosslinked, or a polyurethane thermoplastic or a vulcanized polymer. The foamed polymers are foamed using a chemical or physical blowing agent. Another foam can be flexible polyurethane foam made by the reaction of diisocyanates or polyisocyanates with a polyol in the presence of a blowing agent, a surfactant, and a catalyst with or without external heating during its foaming. The thickness range of the cushion layer 2 can be from 0.032 inches to 1.250 inches with a IFD/ILD of 20 pounds to 200 lbs. and preferably 60 lbs. to 70 lbs. The foam of the cushion layer 2 can be closed or open cell, but preferably the cushion layer 2 foam is made of an open cell foam. A waterproof coating layer 3 may be comprised of a film or liquid coating with a water or solvent carrier that evaporates, and the coating becomes a water or moisture proof layer that is also resistant to other fluids.

(64) In another embodiment, FIG. 3 shows a partial cross section, taken at line I in FIG. 23, of a helmet shell 9 with a flexible layer 4, made from a thermoplastic polymer that may or may not be crosslinked or a vulcanized polymer with a Flexural Modulus ranging from 50 MPa to 600 MPa. Flexible layer 4, can be non-foamed or slightly foamed. Cushion layer 2 has previously been described with respect to FIG. 1 and FIG. 2.

(65) FIGS. 3A through 3B show alternate embodiments of cushion layer 2. Cushion layer 2 may be a continuous layer or it can be comprised of multiple shapes such as an elongated square or cylinder. These cushion layer components may be spaced to enable the foam to compress and absorb the torsional rotational forces of the wearer's head in addition to the impact forces. As shown in FIGS. 3A and 3B, cushion layer 2 may be comprised of square or rectangular segments affixed to flexible layer 4. As shown in FIGS. 3C and 3D, cushion layer 2 may be comprised of cylindrical segments affixed to flexible layer 4.

(66) The purpose of spacing between the foam shapes is to enable the head to rotate yet still have the foam absorb the rotational torsion forces as well as the impact forces. A concussion can be caused by stretching and tearing of the neurons and Axons. Axons are electrical pathways that connect neurons. The Axons can tear and lead to the death of neurons and Axons adjacent to the neurons and Axons that were originally damaged. By enabling the head to rotate, and decelerate it with cushioning foam, it will mitigate or at lease reduce the trauma from the rotational torsion forces that could tear the neurons and Axons.

(67) In another embodiment, FIG. 4 shows a partial cross section, taken at line I in FIG. 23, of a helmet shell 9 comprised of a flexible layer 4 with a flexural modulus ranging from 50 MPa to 600 MPa, a cushion layer 2 and a waterproof coating layer 3.

(68) In another embodiment, a first cushion layer 2 and a second cushion layer 2 may be made of one or more layers. In an arrangement with more than one cushion layer 2, each layer may or may not be made of a different material. In some embodiments, the cushion layer 2 attached to the external helmet shell 9 may have a higher specific gravity making it less flexible than that of the layer of the cushion layer 2 furthest from the external helmet shell 9. It should be appreciated that more or fewer cushion layers 2 may be used. In some embodiments, some or all cushion layer 2 may be made of the same material. In some embodiments, a cushion layer 2 may have a different thickness and/or specific gravity.

(69) FIG. 5 shows a partial cross section, taken at line I in FIG. 23, of an external helmet shell 9 comprised of a slightly foamed layer 1, with a flexural modulus ranging from 50 MPa to 600 MPa, a cushion layer 2, a second helmet shell 9 layer made from a non-foamed flexible layer 4 that has a flexural modulus ranging from 50 MPa to 600 MPa, and a second cushion layer 2. Where more than one helmet shell is used, the helmet shells should be stacked with respect to each other. Each of the helmet shells has an external side facing away from the head of the wearer and an internal side facing toward the head of the wearer. Being stacked, the external side of an inner helmet shell (i.e. a helmet shell closer to the wearer's head) will be in contact with the internal side of an outer helmet shell (i.e. one further from the wearer's head).

(70) FIG. 6 shows a partial cross section, taken at line I in FIG. 23, of a helmet shell 9 comprised of a slightly foamed layer 1 having a flexural modulus ranging from 50 MPa to 600 MPa, a cushion layer 2, and a second helmet shell 9 layer made from a non-foamed flexible layer 4 having a flexural modulus ranging from 50 MPa to 600 MPa, a second cushion layer 2, and an waterproof coating layer 3.

(71) FIG. 7 shows a partial cross section, taken at line I in FIG. 23, of a helmet shell 9 with a non-foamed flexible layer 4, a foam cushion layer 2, a second helmet shell 9 layer made from non-foamed flexible layer 4, and a second foam cushion layer 2.

(72) FIG. 8 shows a partial cross section, taken at line I in FIG. 23, of a helmet shell 9 with a non-foamed flexible layer 4, a foam cushion layer 2, a second helmet shell 9 layer made from non-foamed flexible layer 4, a second foam cushion layer 2 and a waterproof coating layer 3.

(73) FIG. 9 shows a partial cross section, taken at line I in FIG. 23, of a helmet shell 9 with a non-foamed flexible layer 4, having a flexural modulus ranging from 50 MPa to 600 MPa, a foam cushion layer 2, and a second foam cushion layer 2.

(74) FIG. 10 shows a partial cross section, taken at line I in FIG. 23, of a helmet shell 9 with a non-foamed flexible layer 4 having a flexural modulus ranging from 50 MPa to 600 MPa, a foam cushion layer 2, a second foam cushion layer 2 and an waterproof coating layer 3.

(75) Another aspect of this patent application has a separator layer 5 containing air spaces or channels through the separator layer 5 to allow for increased air flow. The inside of a helmet shell 9 can become warm and since the cushion layer 2 is a foam and foams are an insulator, it can retain heat within the helmet shell 9. Creating air channels and openings in the helmet shell 9 cushion layer 2 and other layers allows for ventilation and helps mitigate some of this heat. The separator layer 5 can promote improved air flow between the cushion layer 2 and the wearer's head. Additional air circulation can be achieved with a device to force air flow such as a fan or a CO.sub.2 cartridge with a flow control mechanism.

(76) FIG. 11 shows a helmet shell 9 with a non-foamed flexible layer 4 having a flexural modulus ranging from 50 MPa to 600 MPa, a foam cushion layer 2, an optional second non-foamed flexible layer 4 having a flexural modulus ranging from 50 MPa to 600 MPa, an optional second foam cushion layer 2, a waterproof coating layer 3, and a separator layer 5. The separator layer 5 can be combined with any of the depictions in the drawings shown in FIG. 1 through FIG. 17.

(77) In another aspect of this patent application, the helmet shell 9 surface is made of a flexible layer having a flexural modulus ranging from 50 MPa to 600 MPa that is covered with multiple particles made of rigid particles 20 layer having a flexural modulus ranging above 600 MPa. The size of the rigid particles 20 layer on the helmet shell 9 can vary in size from 0.125 to 6 across. FIG. 12 and FIG. 13 shows a helmet shell 9 surface made of a non-foamed flexible layer 4. The rigid particles 20 can be multi sided having a hexagonal shape or without sides in the shape of a circle. The rigid particles may be adhered to the flexible layer such that rigid particles 20 are raised above the surface of the flexible layer. Further, the shape and size of the multiple rigid particles 20 layer material can be achieved by embossing them into helmet shell 9 or a flexible layer Helmet Shell 9. The rigid particles serve to provide a thicker surface for strength and durability, but still allowing flexibility as the rigid particles can move toward each other as the helmet shell compresses.

(78) In FIG. 12, the rigid particles 20 covering the top of helmet shell 9 may have a hexagon shape. The hexagon shape can also be achieved by embossing them into rigid, slightly foamed shell, or a non-foamed flexible layer 4 of helmet shell 9. FIG. 13 shows rigid particles 20 in a larger hexagon shape.

(79) In some embodiments, the combination of the internal cushion layer 2 with the flexible head-protecting helmet shell 9 allows the helmet shell 9 to provide the best impact protection. In all embodiments, the combination of the internal cushion layer 2 with the flexible layer helmet shell 9 allows the helmet shell 9 to maximize protection from the energy of an impact force. In all embodiments, the flexible layer helmet shell 9 absorbs and spreads the impact force over a larger area to reduce the force applied per square inch and in combination with the internal cushion layer 2 absorbs part or all of the energy from an impact force.

(80) FIGS. 14-17 shows cross sectional views of a protective helmet 21 taken at line II in FIG. 39 using the material layers depicted in FIG. 7 which shows a helmet shell 9 with a non-foamed flexible layer 4, a foam cushion layer 2, a second non-foamed flexible layer 4, and a second foam cushion layer 2. The graphics in FIG. 14 through FIG. 17 demonstrate the technology of this patent application. In FIG. 14, an impact force is contacting the external helmet shell 9. In FIG. 15, the impact force flexes the external helmet shell 9 downward. This spreads the impact force over a larger area, which reduces the pounds per square inch (psi) of the force. As the impact force compresses and flexes the external helmet shell 9, the first cushion layer 2 compresses and absorbs the energy from the impact force. Some or all of the energy is dissipated and mitigated; thus, the protective helmet 21 design reduces the potential injury to the protective helmet 21 wearer. FIG. 16 and FIG. 17 show the effect of a larger impact force that compresses and flexes the second flexible layer 4 downward, compressing the second cushion layer 2. When the second flexible layer 4 and the second cushion layer 2 have compressed, most if not all of the energy from the larger impact force has been dissipated and mitigated, causing little if any effect to the brain of the protective helmet 21 wearer.

(81) Protective helmet 21 may be fitted with a protective barrier 8, intended to protect the protective helmet 21 wearer's facial area and eyes. Some helmets may be fitted with a facial barrier intended to protect the wearer's facial area and eyes. Many of the current barriers are made of bars of steel rods crisscrossing in a configuration referred to as a facemask to prevent the entry of a ball, puck, stick, a hand, or other foreign objects that could injure the helmet wearer. Often, this barrier is bolted on the front top of the helmet and bolted at a spot on each side using a clip that surrounds the steel rod and has an opening for a bolt. If the side bolts are removed, the barrier can be pivoted and rotated off the wearer's face. This also enables easier removal of the helmet. If the wearer of the helmet suffers a head, facial, or neck injury, the person treating the injury may want to remove the helmet. Typically, removing the side bolts or screws enables the pivoting of the barrier off the wearer's face for easier removal of the barrier. However, removing the bolts requires a screwdriver, which may or may not be available. In addition, even if a screwdriver is available, it takes time and time may be of essence.

(82) By contrast, the invention provides for a locking mechanism 7 which permits easy removal of the protective barrier 8. FIG. 18 through FIG. 21 and FIGS. 22, 23, 39 and 40 show a locking mechanism 7, to secure the protective barrier 8, to the protective helmet 21. The protective helmet 21 of the invention provides for a protective barrier 8 which may be easily removed to permit above the wearer's face to permit the wearer to see, drink and interact more easily and which permits easier removal of protective helmet 21.

(83) Components of the locking mechanism 7 include latch 10, fixture assembly 11, hook 12, button 13, and rivet 14. One end of latch 10 may be inserted into fixture assembly 11 and configured to engage hook 12 which moves in conjunction with button 13. When the button 13 is depressed, it should push latch 10 away from the hook 12 to release latch 10 from the locking mechanism 7. The other end of latch 7 may be secured to protective barrier 8. By pushing the button 13, in seconds, the protective barrier 8 is released and removed to access the wearer's face and/or remove the protective helmet 21.

(84) The latch 10 can be interchanged or replaced with extended flexible component 17. Extended flexible component 17 may be designed to be flexible to allow movement of protective barrier 8 relative to helmet shell 9. In a similar manner, if extended flexible component 17 is utilized, on end of extended flexible component should fit into fixture assembly 11, the end being configured, similar to the latch, to engage hook 12 and button 13. When the button 13 is depressed, it should push extended flexible component 17 away from the hook 12 to release extended flexible component 17 from the locking mechanism 7. Extended flexible component 17 may also be connected at its other end to protective barrier 8. FIG. 18 through FIG. 21 show one variation of the embodiment of the locking mechanism 7.

(85) FIG. 22, FIG. 23, FIG. 39 and FIG. 40 show a protective helmet 21 with a locking mechanism 7, located on each side of the helmet and in the center front of the helmet to secure the protective barrier 8, to the helmet shell 9. Some protective helmets 21 are fitted with a protective barrier 8, intended to protect the helmet wearer's eyes, mouth and other facial features. The locking mechanism 7 has an extended flexible component 17 that holds the protective barrier. The extended flexible component 17 attaches the protective barrier 8 to the helmet shell 9 and may be inserted into fixture assembly 11 to engage the hook 12. When an impact force strikes the helmet, the extended flexible component 17 enables the helmet shell 9 to flex inward to absorb and mitigate the energy from an impact force while still permitting the protective barrier to remain in a position in front of the wearer's face. The extended flexible component 17 can be made of spring steel or any suitable material that is flexible and has sufficient the strength not to fail.

(86) When the button 13, of the locking mechanism 7, is suppressed or pushed in, the protective barrier 8 can be released from the protective helmet 21 and can be easily pivoted and rotated off the wearer's face or be completely removed. If the wearer of the protective helmet 21 suffers a head, facial, or neck injury, the person treating the protective helmet 21 wearer's injury will want to remove the protective barrier 8 and protective helmet 21. In seconds, the protective barrier 8, can be released and can be removed by pushing in button 13. This also enables easy removal of the protective helmet 21. FIG. 22, FIG. 23, FIG. 39, and FIG. 40 show an embodiment of the protective helmet 21 with the locking mechanism 7.

(87) FIG. 24 and FIG. 25 show a cross section of a helmet, taken at line III in FIG. 23 of a protective helmet 21 with a locking mechanism 7, located on each side of the helmet. Not shown is the locking mechanism 7, on the center front of the helmet. The locking mechanism 7, secures the protective barrier 8, to the helmet shell 9. Some protective helmets 21 are fitted with a protective barrier 8, intended to protect the helmet wearer's facial area and eyes. The protective barrier 8, may be constructed of bars of steel rods crisscrossing in a configuration referred to as a facemask to prevent the entry of a ball, stick, a hand, or other foreign objects that could injure the helmet wearer. A clear plastic protective barrier 8 can also be used. The latch 10 of locking mechanism 7 has an extended flexible component 17 that holds the protective barrier 8. The extended flexible component 17 attaches the protective barrier 8 to the protective helmet 21. When the protective helmet 21 wearer experiences an impact force strike to the side of the protective helmet 21 as shown in FIG. 25, the extended flexible component 17 enables the helmet shell 9 to flex inward to absorb and mitigate the energy from an impact force on the side of the helmet, and the flexing of the helmet reduces the rate of deceleration, distributes the energy of an impact force over a larger area of the protective helmet 21 to reduce the energy intensity per square inch area, and absorbs and mitigates the energy of an impact force. If the helmet shell 9 cannot flex from an impact force, the helmet shell 9 could transfer the energy from an impact force like a Newton's Cradle to the skull of the wearer of protective helmet 21 that could cause a brain injury. The extended flexible component 17 can be made of spring steel or any suitable material that is flexible and has sufficient strength not to fail. FIG. 24 and FIG. 25 shows one variation of the embodiment of the protective helmet 21 with the locking mechanism 7.

(88) FIG. 26 and FIG. 27 show a helmet configuration which utilizes a locking mechanism 7 to secure the protective barrier 8, and the protective helmet 21. The locking mechanism 7 and use of either a latch 10 or an extended flexible component 17 enables the protective barrier 8, to be rotated upwards. This enables easy removal of the protective helmet 21, and access to the wearer's facial area in the event of an injury.

(89) The protective barrier 8 may be secured to a pivot mechanism such as a hinge or another flexible component at the front top of the helmet and attached on each side of the protective helmet 21 with a locking mechanism 7. When the button 13, of the locking mechanism 7, is suppressed or pushed in, the latch 10 or an extended flexible component 17 is released and enables the protective barrier 8, to be pivoted and rotated off the wearer's face or removed. When the protective barrier 8 is pivoted or rotated open or removed, making the protective helmet 21 easier to remove from the wearer's head. If the wearer of the protective helmet 21 suffers a head, facial, or neck injury, the person treating the wearer's injury will want to remove the protective helmet 21. Typically, several screws or bolts must be removed to enable the protective barrier 8, to be pivoted off the wearer's face. Removing screws or bolts requires a screwdriver, which may or may not be available. In addition, even if a screwdriver is available, it takes time and time may be of essence. In seconds, the protective barrier 8 can be removed by pushing in the button 13 of the locking mechanism 7. FIG. 26 and FIG. 27 show one variation of an embodiment of the protective helmet 21 with the locking mechanism 7 and protective barrier 8 connected in this manner.

(90) FIG. 28 and FIG. 29 show another embodiment of the protective helmet 21 in which the entire frontal portion of the helmet can rotate away from the wearer's face. FIG. 28 shows a left side view of a helmet with a hinge 15, on its top and a locking mechanism 7, on each side of the helmet with an extended flexible component 17. FIG. 29 shows a left side view of a protective helmet 21 with the locking mechanism 7 and the extended flexible component 17 unlocked and the helmet swung open and held together by a hinge 15. One of the advantages of this design is that it allows easy removal of the protective helmet 21 to allow quick and easy access to the wearer of the protective helmet 21 in the event of an injury, especially severe face and/or neck injury. FIG. 28 and FIG. 29 show an alternate embodiment of the protective helmet 21 with the locking mechanism 7.

(91) FIGS. 30, 31, and 32 show an alternate embodiment of a protective helmet 21 without a protective barrier in front of the wearer's face. This type of helmet may be used in other sports, for example, a baseball batting helmet where a protective facial barrier is not typically used. FIG. 30 shows a top view of a protective helmet 21 with a hinge 15, on its top and a locking mechanism 7 with a latch 10 or extended flexible component 17 on each side of the protective helmet 21. FIG. 31 shows a side view of a protective helmet 21 with a hinge 15, on its top and a locking mechanism 7, on each side of the protective helmet 21. FIG. 32 shows a left side view of a protective helmet 21 with the locking mechanism 7, unlocked and the protective helmet 21 swung open and held together by a hinge 15. One of the advantages of this design is that it enables easy removal of the protective helmet 21 to allow quick and easy access to the wearer of the protective helmet 21 in the event of an injury, especially severe face and/or neck injury.

(92) In another aspect of this patent application, an adjustment locking mechanism 16 is installed on the second flexible layer helmet shell 9 (an inner helmet shell closest to the head of a wearer). The adjustment locking mechanism 16 is typically position on the middle of the lower back of the second flexible layer helmet shell 9. The adjustment locking mechanism 16 is intended to obtain a tighter and more secure fit of the second flexible layer helmet shell 9 on the wearer head. When the adjustment locking mechanism 16 is opened, it enables easier removal of the protective helmet 21. The adjustment locking mechanism 16 can be adjusted to any position between fully opened and closed.

(93) FIG. 33 and FIG. 34 shows an adjustment locking mechanism 16 for the second helmet shell 9 with a flexible Layer 4 with view taken at line IV in FIG. 40. The adjustment locking mechanism 16, would typically be position on the middle of the lower back of the second helmet shell 9 with a flexible layer 4. FIG. 33 shows the adjustment locking mechanism 16, in the open position where the second helmet shell 9 with a flexible layer 4 is fully opened. FIG. 34 shows the adjustment locking mechanism 16, in the closed position the second helmet shell 9 with a flexible layer 4 is closed. When adjustment locking mechanism 16 is in the open position, lever 36 is up and connected to engager 37. Lever 36 is also attached to secured base 35 as shown. Engager 37 may be inserted into one of several spaced teeth 38 in toothed base 19. As lever 36 is pulled down toward the closed position, it pulls on engager 37 which pulls toothed base 19 closer to secured base 35. Toothed base 19 and secured base 35 are attached to two segments of flexible layer 4 separated by a gap. As toothed base 19 and secured base 35 are pulled closer together, the segments of flexible layer are pulled together, tightening flexible layer 4 around the head of the wearer.

(94) FIG. 35 and FIG. 36 show a portion of a helmet shell 9 of a protective helmet as seen in FIG. 40, although the second helmet shell 9 in FIG. 40 is not depicted with intermeshing notches. As shown in FIGS. 35 and 36, portions of a second helmet shell 9 may come together and maintain their alignment through intermeshing notches. An adjustment locking mechanism 16 may secure and hold together the segments of the helmet shell 9. The second helmet shell 9 with a flexible layer 4 may be configured with intermeshing notches 22 that can be any geometric shape that will intermesh to provide protection when in the open position and to enable closing of the second helmet shell 9 with a flexible layer 4 without overlapping the second helmet shell 9 with a flexible layer 4 upon itself. The adjustment locking mechanism 16 may also be positioned on the middle of the low back of the second helmet shell 9 with a flexible layer 4. FIG. 35 shows the adjustment locking mechanism 16, in the open position where the second helmet shell 9 with a flexible layer 4 is fully opened. The second helmet shell 9 with a flexible layer 4 in FIG. 36 shows the adjustment locking mechanism 16, in the closed position where the second helmet shell 9 with a flexible layer 4 is completely closed. The adjustment locking mechanism 16 can be adjusted to any position between fully opened and closed.

(95) FIG. 37 and FIG. 38 show an alternative design for an adjustment locking mechanism 16. In this embodiment, thread screw 18 enables the adjustment of the distance between toothed base 19 and secured base 35. Adjustment locking mechanism 16 operates in a manner as described above; however, in addition, thread screw 18 may be turned clockwise or counterclockwise to provide a fine adjustment to the level of tightness of flexible layer 4 around the head of the wearer. While two different design configurations are disclosed in this patent application, there are several variations to them.

(96) Aspects of the invention are described herein with reference to certain illustrative embodiments and the figures. The illustrative embodiments described herein are not necessarily intended to show all aspects of the invention, but rather are used to describe a few illustrative embodiments. Thus, aspects of the invention are not intended to be construed narrowly in view of the illustrative embodiments. In addition, it should be understood that aspects of the invention may be used alone or in any suitable combination with other aspects of the invention.