CA2944737A1

CA2944737A1 - Adaptive fit helmet and method for fitting helmet to customer head

Info

Publication number: CA2944737A1
Application number: CA2944737A
Authority: CA
Inventors: Michael J. Musal
Original assignee: Bell Sports Inc
Current assignee: Bell Sports Inc
Priority date: 2014-04-03
Filing date: 2015-02-05
Publication date: 2015-10-08
Also published as: US20150282550A1; EP3116339A4; CN106455734B; JP2017509809A; WO2015152992A1; CN106455734A; EP3116339A1; AU2015241563A1; EP3116339B1

Abstract

An adaptive fit helmet can comprise an outer shell, and energy-absorbing material, and a fit system. The outer shell can comprise a top portion, a side portion, and an outer expansion area that extends along an interface of the top portion and the side portion from a temple area of the outer shell to a lower exterior edge of the outer shell. The energy-absorbing material can be disposed withing the outer shell, wherein the energy-absorbing material further comprises a top portion, a side portion, and an inner expansion area between edges of the top portion and the side portion of the energy-absorbing material such that the inner expansion area corresponds with the outer expansion area. The fit system can comprise a belt and a fit system mechanism that control a three-dimensional size and shape of both the outer shell and the energy-absorbing material.

Description

2 PCT/US2015/014558 ADAPTIVE FIT HELMET AND METHOD
FOR FITTING HELMET TO CUSTOMER HEAD
TECHNICAL FIELD
[0001] This disclosure relates to an adaptive fit helmet and a method for fitting a helmet to a customer's head. The adaptive fit helmet can be employed wherever a conventional helmet is used, and can be a flexible and adjustable helmet that can be used for a skier, skater, hockey player, snowboarder, or other snow or water athlete, a cyclist, football player, baseball player, lacrosse player, polo player, climber, auto racer, motorcycle rider, motocross racer, sky diver or any other athlete in a sport, construction worker or other person who is in need of protective headgear.
BACKGROUND
[0002] Protective headgear and helmets have been used in a wide variety of applications and across a number of industries including sports, athletics, construction, mining, military defense, and others, to prevent damage to a user's head and brain.
Damage and injury to a user can be prevented or reduced by helmets that prevent hard objects or sharp objects from directly contacting the user's head. Damage and injury to a user can also be prevented or reduced by helmets that absorb, distribute, or otherwise manage energy of an impact.

[0003] For helmet-wearing athletes in many applications, such as sports, beyond the safety aspects of the protective helmet, additional considerations can include helmet fit and airflow through the helmet. Improvements in fit comfort and airflow can reduce distractions to the athlete and thereby improve performance. The adaptive fit helmet and method for using the same, as disclosed in this document, relate to safety, as well as improvements in fit, airflow, and comfort without reducing safety for customers of varying head shapes.

[0004] Conventional helmet creation technology has designed safety helmetry with the assumption that human heads are similar and that adjustments to the standard helmet can be made by adding different thicknesses of padding between the customer's head and the inner surface of the helmet. Sometimes additional comfort padding has been added as part of a conventional fit system that adjusts a size of the comfort padding within a helmet of a fixed or constant size. These assumptions, however, have resulted in helmets that do not fit correctly, tend to slip around on the customer's head, rattle on the customer's head when vibration occurs in the customer's body during activities in the sport, or to create pressure points on the customer's head and face to try to keep the helmet in place even though the padding does not fit correctly or where the customer's head is too large for sufficient padding disposed between the head and the protective material of the helmet.
SUMMARY

[0005] A need exists for an adaptive fit helmet and a method for making the same.
Accordingly, in an aspect, an adaptive fit helmet can comprise an outer shell comprising a top portion, a side portion, and an outer expansion area that extends along an interface of the top portion and the side portion from a temple area of the outer shell to a lower exterior edge of the outer shell. An energy-absorbing material can be disposed within the outer shell, wherein the energy-absorbing material further comprises a top portion, a side portion, and an inner expansion area between edges of the top portion and the side portion of the energy-absorbing material such that the inner expansion area corresponds or aligns with the outer expansion area. A fit system can comprise a belt coupled to the side portion of the outer shell and a fit system mechanism coupled to the top portion of the outer shell, wherein a position of the fit system controls both a three-dimensional size and shape of the outer shell as well as a three-dimensional size and shape of the energy-absorbing material.

[0006] The adaptive fit helmet can further comprise the belt of the fit system comprising a rack and the fit system mechanism comprising a pinion such that the rack and pinion are configured to both push and pull the top portion and the side portion of the outer shell to either increase or decrease the three-dimensional size and shape of both the outer shell and the energy-absorbing material. The outer shell can comprise a flexible outer shell and the energy-absorbing material comprises expanded polystyrene (EPS), expanded polyurethane (EPU or EPTU), expanded polyolefin (EPO), expanded polypropylene (EPP), or vinyl nitrile (VN). The fit system can control the three-dimensional size and shape of the outer shell between the temple area and an ear area of the outer shell. The interface of the top portion and the side portion the outer shell can comprise a U-shape and the inner expansion area of the energy-absorbing material also comprises a U-shape. The top portion of the outer shell and the side portion of the outer shell can be formed as two discrete portions, and the top portion of the outer shell and the side portion of the outer shell are coupled to each other. A method of using the adaptive fit helmet can comprise adjusting the fit system so that a flexibility of the adaptive fit helmet allows for a size, a shape, and a contour of the adaptive fit helmet to change to match a shape, a size, and a contour of a head of a user.

[0007] In another aspect, an adaptive fit helmet can comprise an outer shell comprising an outer expansion area that extends from a temple area of the outer shell to a lower exterior edge of the outer shell. An energy-absorbing material can be disposed within the outer shell. A fit system can comprise a belt coupled to the outer shell and a fit system mechanism coupled to the outer shell and the belt, wherein a position of the fit system controls a three-dimensional size and shape of the outer shell.

[0008] The adaptive fit helmet can further comprise the belt of the fit system comprising a rack and the fit system mechanism comprising a pinion such that the rack and pinion are configured to both push and pull the outer shell to either increase or decrease the three-dimensional size and shape of the outer shell. The outer shell can comprise a flexible outer shell and the energy-absorbing material comprising EPS, EPU, EPO, EPP, or VN.
The fit system can control the three-dimensional size and shape of the outer shell in front of an ear opening of the outer shell. The helmet can taper in towards back bottom corners of the lower exterior edge of the outer shell so that a taper ratio of a width between the back bottom corners to a width of the helmet (Wb:W) for the adaptive fit helmet in an open position is larger than a taper ratio Wb:W for the adaptive fit helmet in the closed position. The position of the fit system can be configured to control both a two-dimension length and two-dimensional width of the outer shell simultaneously and to cause the outer shell to flex.

[0009] In another aspect, a method of using an adaptive fit helmet can comprise an outer shell comprising an outer expansion area that extends along the outer shell to a lower exterior edge of the outer shell. An energy-absorbing material can be disposed within the outer shell, wherein the energy-absorbing material further comprises an inner expansion area that corresponds or aligns with the outer expansion area. A fit system can comprising a belt coupled to the outer shell and a fit system mechanism coupled to the outer shell and the belt, wherein a position of the fit system simultaneously controls both a size and shape of the outer shell as well as a size and shape of the energy-absorbing material.

[0010] The method of using the adaptive fit helmet can further comprise the belt of the fit system comprising a rack and the fit system mechanism comprising a pinion such that the rack and pinion are configured to alternately push and pull the outer shell to either simultaneously increase or decrease the size and shape of the outer shell as well as the size and shape of the energy-absorbing material. The outer shell can comprise a flexible outer shell and the energy-absorbing material can comprise EPS, EPU, EPO, EPP, or VN. The fit system can control the size and shape of the outer shell and the energy-absorbing layer in an area of the adaptive fit helmet between a temple area and an ear area of the adaptive fit helmet. The inner expansion area can comprise a U-shape. The outer shell can comprise two discrete portions that are coupled to each other at a flange away from the outer expansion area. A
method of using the adaptive fit helmet can comprise adjusting the fit system so that a flexibility of the adaptive fit helmet allows for a size, a shape, and a contour of the adaptive fit helmet to change to match a shape, a size, and a contour of a head of a user.
BRIEF DESCRIPTION OF THE DRAWINGS

[0011] FIGs. lA and 1B show views of an embodiment of an adaptive fit helmet from a front/side perspective and a back/side perspective.

[0012] FIGs. 2A and 2B show embodiments of adaptive fit helmets comprising outer shells comprising one portion separated from another portion.

[0013] FIG. 3 shows a plan view of an inner surface of an embodiment of an adaptive fit helmet comprising an energy-absorbing material.

[0014] FIGs. 4A and 4B show embodiments of a fit system disposed within an adaptive fit helmet.

[0015] FIGs. 5A and 5B show rear views of an embodiment of an adaptive fit helmet adjusted to large and small sizes.

[0016] FIG. 6 shows a top view of an embodiment of an adaptive fit helmet comprising vents.

DETAILED DESCRIPTION

[0017] This disclosure, its aspects and implementations, are not limited to the specific helmet or material types, or other system component examples, or methods disclosed herein.
Many additional components, manufacturing and assembly procedures known in the art consistent with helmet manufacture are contemplated for use with particular implementations from this disclosure. Accordingly, for example, although particular implementations are disclosed, such implementations and implementing components may comprise any components, models, types, materials, versions, quantities, and/or the like as is known in the art for such systems and implementing components, consistent with the intended operation.

[0018] The word "exemplary," "example," or various forms thereof are used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as "exemplary" or as an "example" is not necessarily to be construed as preferred or advantageous over other aspects or designs. Furthermore, examples are provided solely for purposes of clarity and understanding and are not meant to limit or restrict the disclosed subject matter or relevant portions of this disclosure in any manner. It is to be appreciated that a myriad of additional or alternate examples of varying scope could have been presented, but have been omitted for purposes of brevity.

[0019] While this disclosure includes a number of embodiments in many different forms, there is shown in the drawings and will herein be described in detail particular embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principles of the disclosed methods and systems, and is not intended to limit the broad aspect of the disclosed concepts to the embodiments illustrated.

[0020] This disclosure provides a device, apparatus, system, and method for providing a protective adaptive helmet that can include an outer shell and an inner energy-absorbing layer, such as foam. The adaptive helmet can be both flexible and adjustable and that can be used for a skier, skater, hockey player, snowboarder, or other snow or water athlete, a cyclist, football player, baseball player, lacrosse player, polo player, climber, auto racer, motorcycle rider, motocross racer, sky diver or any other athlete in a sport.
Other industries also use protective headwear, such as a construction, soldier, fire fighter, pilot, or other worker in need of a safety helmet, where similar technologies and methods may also be applied. Each of the above listed sports or activities can use a helmet that includes either single or multi-impact rated protective material base that is typically, though not always, covered on the outside by a decorative cover and includes comfort material on at least portions of the inside, usually in the form of comfort padding.

[0021] FIGs. lA and 1B show perspective views of a helmet or adaptive fit helmet 10. FIG. lA shows a perspective view of a front and left side of an adaptive fit helmet 10, while FIG. 1B shows a perspective view of back and left side of the helmet 10. As used herein, the terms front, back, left, and right, are used for convenience in describing a non-limiting example of the helmet 10 with respect to a direction or orientation of a person wearing the helmet. As such, different and opposite helmet orientations can also be used in reference to the helmet 10.
The helmet 10 can also comprise an outer shell 20 and an energy-absorbing material 60.

[0022] The outer shell 20 can be made of a flexible or semi-flexible material that can comprise plastics, including Acrylonitrile Butadiene Styrene (ABS), polycarbonate, Kevlar, fiber materials including fiberglass or carbon fiber, or other suitable material. A
non-limiting example of a possible ABS plastic that can be used for the outer shell is Cycolac0 EX39, by GE Plastics.
The outer shell 20 can comprise a flexural strength greater or equal to 2.76 gigapascals (or 400,000 pounds per square inch (psi)). The outer shell 20 can also comprise a flexural strength greater or equal to 1.86 gigapascals (or 270,000 pounds per square inch (psi)). The outer shell 20 is typically made hard enough to resist impacts and punctures, and to meet the related safety testing standards, while being flexible enough to deform slightly during impacts to absorb energy through deformation, thereby contributing to energy management and protection of the helmet wearer.

[0023] Outer shell 20 can comprise one or more portions, segments, or pieces coupled together, such as two, three, four, or any number of portions, that allow for the portions or segments of the outer shell to be moved and adjusted relative to one another. Accordingly, relative movement of portions or segments of the outer shell can allow for a range of helmet sizes that permit a single helmet to adapt to a particular head size and head shape for multiple users, thereby improving helmet comfort and performance. The flexibility of the one or more materials used for the outer shell may also be selected in conjunction with the shape, design, size, and dimensions of the multiple portions or segments of the outer shell to allow for a degree or amount of movement desired to adapt to a targeted range of sizes.

[0024] As a non-limiting example, outer shell 20 is discussed below with respect to two portions: a top or central portion 30 of the outer shell 20, and a side portion 40 of the outer shell 20. Thus, while outer shell 20 can comprise two portions, any other number of portions can also be used for providing the benefits and advantages described in greater detail below.
Significantly, and as discussed in greater detail below, one or more portions of the outer shell 20 can be formed as discrete portions or pieces, and alternatively, one or more portions of the outer shell 20 can also be integrally formed or permanently coupled to each other.

[0025] An interface 50 can exist between different portions, sections, or segments of outer shell 20. Interface 50 can be formed or exist as channels, slits, gaps, slots, openings, or overlapping tabs or flanges that follow a shape, curve, or outer edge of the helmet 10. Interface 50 can be formed comprising a straight line, one or more arcs or curve, or with a meandering, undulating, or interlocking design along a span or distance of the interface 50. For embodiments of outer shell 20 comprising top portion 30 and side portion 40, a shape of the interface 50 between the top portion 30 and the side portion 40 can comprise a U-shaped interface 52 at the top front of the helmet, and a rear tapered interface 56 at a rear of the helmet. The U-shaped interface 52 can comprise two parts, a lateral portion 53 that forms the bottom or base of the U-shape, and longitudinal portions 54 that form the sides of the U-shape, which are described in greater detail below.

[0026] The U-shaped interface 52 can comprise a lateral portion 53 that can extend horizontally, either partially, completely, or substantially horizontally, across a width W of the helmet, between left and right sides of the helmet at a front portion of the helmet above a face port, visor, or lip 41of side portion 40 by following a shape, curve, or outer surface of the helmet 10. The lateral portion 53 of the U-shaped interface 52 can be connected to two longitudinal portions that extend along a portion of a length L of the helmet between front and rear portions of the helmet 10. Longitudinal portions 54 of U-shaped interface 52 can extend horizontally, either partially, completely, or substantially horizontally, along a length L
of the helmet between front and rear portions the helmet. The longitudinal portions 54 of U-shaped interface 52 can extend along opposing left and right sides of the helmet as left longitudinal portion 541 and right longitudinal portion 54r, respectively. In some embodiments, an average direction or orientation of the longitudinal portions 54 can be substantially perpendicular, transverse, or orthogonal, to lateral portion 53.

[0027] The rear tapered interface 56 can be positioned at a rear of the outer shell 20 between top and bottom portions of the helmet by following a shape, curve, or outer surface of the helmet 10. The rear tapered interface 56 can be formed of rear tapered interface edges 57 that can extend vertically, either partially, completely, or substantially vertically, along a height H of the helmet 10. Rear tapered interface edges 57 can extend along opposing left and right sides of rear tapered interface 56 as left rear tapered edge 571 and right rear tapered edge 57r, respectively. In some embodiments, an average direction or orientation of rear tapered interface edges 57 can be substantially perpendicular, transverse, or orthogonal, to the longitudinal portions 54. The rear tapered interface edges 57 can intersect or be joined with the longitudinal portions 54 as well as a lower exterior edge 22 of outer shell 20.

[0028] Thus, interface 50 can exist between adjacent portions of outer shell 20, such as between top portion 30 and side portion 40 as described above. Accordingly, edges, ridges, or lips of top portion 30 and side portion 40 can define a boundary or outer edge of interface 50 as described herein. In some instances, the edges, ridges, or lips of top portion 30 and side portion 40 can be at an outer edge or limit of the top portion 30, the side portion 40, or any portion of outer shell 20. In other instances, the edges, ridges, or lips of top portion 30 and side portion 40 can be set back, or offset, from an outer edge or limit of the top portion 30, the side portion 40, or any portion of outer shell 20 so that an outer expansion area 51 is between the interface 50, and an overlap exists between top portion 30 and side portion 40, to cover a user's head and to prevent passage from an exterior of the helmet 10 to the interior of the helmet 10 through the interface 50. In either event, the edges, ridges, or lips of top portion 30 and side portion 40 can have lengths, sections, portions, or segments, as set forth in greater detail below, that correspond to the have lengths, sections, portions, or segments of interface 50 described above.

[0029] Thus, as shown throughout the FIGs., including at FIGs. 2A and FIG. 4B, the top portion 30 can comprise a U¨shaped interface edge 32 comprising a lateral portion edge 33 that can extend horizontally, either partially, completely, or substantially horizontally, across the width W of the helmet, between left and right sides of the helmet at a front portion of the helmet by following a shape, curve, or outer surface of the helmet 10. The lateral portion 33 of the U-shaped channel 32 can be connected to two longitudinal portion edges that extend along a portion of the length L of the helmet 10 between front and rear portions of the helmet 10.
Longitudinal portion edges 34 of U-shaped interface edge 32 can extend horizontally, either partially, completely, or substantially horizontally, along the length L of the helmet 10 between front and rear portions the helmet 10. Longitudinal portion edges 34 of U-shaped interface edge 32 can extend along opposing left and right sides of the helmet as left longitudinal portion edge 341 and right longitudinal portion edges 34r, respectively. In some embodiments, an average direction or orientation of longitudinal portion edges 34 can be substantially perpendicular, transverse, or orthogonal, to lateral portion edge 33. In some embodiments, longitudinal portion edges 34 of the helmet 10 will be parallel with respect to each other, but need not be in other embodiments.

[0030] The rear tapered interface edges 37 can be positioned at a rear of the outer shell 20 between top and bottom portions of the helmet by following a shape, curve, or outer surface of the helmet 10. The rear tapered interface edges 37 can extend vertically, either partially, completely, or substantially vertically, along the height H of the helmet 10. Rear tapered interface edges 37 can extend along opposing left and right sides of rear tapered interface 37 as left rear tapered edge 371 and right rear tapered edge 37r, respectively. In some embodiments, an average direction or orientation of rear tapered interface edges 37 can be substantially perpendicular, transverse, or orthogonal, to longitudinal portion edges 34. Rear tapered interface edges 37 can intersect or be joined with longitudinal portion edges 34 as well as a lower exterior edge 22 of outer shell 20.

[0031] Similarly, the side portion 40 can comprise a U¨shaped interface edge 42 comprising a lateral portion edge 43 that can extend horizontally, either partially, completely, or substantially horizontally, across the width W of the helmet, between left and right sides of the helmet at a front portion of the helmet by following a shape, curve, or outer surface of the helmet 10. The lateral portion edge 43 of the U-shaped channel 42 can be connected to two longitudinal portion edges that extend along a portion of the length L of the helmet 10 between front and rear portions of the helmet 10. Longitudinal portion edges 44 of U-shaped interface edge 42 can extend horizontally, either partially, completely, or substantially horizontally, along the length L
of the helmet 10 between front and rear portions the helmet 10. Longitudinal edges 44 of U-shaped interface edge 42 can extend along opposing left and right sides of the helmet as left longitudinal portion edge 441 and right longitudinal portion edges 44r, respectively. In some embodiments, an average direction or orientation of longitudinal edges 44 can be substantially perpendicular, transverse, or orthogonal, to lateral portion edge 43.

[0032] In some embodiments, U¨shaped interface edge 42, lateral portion edge 43, longitudinal portion edges 44, can be parallel or substantially parallel to U¨shaped interface edge 32, lateral portion edge 33, and longitudinal portion edges 34, respectively.
In other embodiments in which interface 50 does not comprise a constant or fixed offset within outer expansion area 51, the above listed features can be divergent or intersecting to allow for particular fit configurations as described in greater detail below.

[0033] The rear tapered interface edges 47 can be positioned at a rear of the outer shell 20 between top and bottom portions of the helmet by following a shape, curve, or outer surface of the helmet 10. The rear tapered interface edges 47 can extend vertically, either partially, completely, or substantially vertically, along the height H of the helmet 10. Rear tapered interface edges 47 can extend along opposing left and right sides of rear tapered interface 47 as left rear tapered edge 471 and right rear tapered edge 47r, respectively. In some embodiments, an average direction or orientation of rear tapered interface edges 47 can be substantially perpendicular, transverse, or orthogonal, to longitudinal edges 44. Rear tapered interface edges 47 can intersect or be joined with longitudinal edges 44 as well as a lower exterior edge 22 of outer shell 20.

[0034] In some embodiments, left rear tapered edge 471 and right rear tapered edge 47r, can be parallel or substantially parallel to left rear tapered edge 371 and right rear tapered edge 37r, respectively. In other embodiments in which interface 50 does not comprise a constant or fixed offset within outer expansion area 51, the above listed features can be divergent or intersecting to allow for particular fit configurations as described in greater detail below.

[0035] Stated differently, FIG. 1B further shows that the top portion 30 of the outer shell 20 can extend down from a top of the outer shell 20, which can be disposed over the top or crown of a user's head when worn. The top portion 30 can extend from the top of the helmet 10 to the lower exterior edge 22 of the outer shell 20 such that the top portion 30 can also include rear tapered interface portion 36 to cover a rear portion of the user's head, including the occipital curve of the user's head, when helmet 10 is worn by the user. The side portion 40 of the outer shell 20 can be formed in a U-shape that can be disposed over the forehead and side portions of the user's head while creating an opening 45 in a center of the U-shape that is configured to receive the top portion, and can be seen, e.g., in FIG. 2A. When placed together, the top portion 30 and side portion 40 of the outer shell 20 can meet or interface along the U-shape as described herein.

[0036] FIGs. 2A and 2B show an embodiment of the helmet 10 in which the outer shell 20 is formed of a number of discrete portions, segments, or pieces that can be separated from each other. More specifically, FIG. 2A shows an embodiment in which top portion 30 can be separate and distinct from side portion 40 so that top portion 30 and side portion 40 can be separately or individually formed. As such, separate top portion 30 and side portion 40 can increase ease of manufacturing and reduce cost with respect to forming a single integrally formed outer shell comprising both a top portion and side portions. In other embodiments, the helmet 10 can be formed as a 1-piece shell comprising a single integrally formed outer shell 20, which can be made in a single process, and can comprise a distinct top portion 30 and a distinct side portion 40 that can be releasably or permanently joined together.

[0037] FIG. 2A shows a perspective view of the front and left side of outer shell 20 similar to the perspective view shown in FIG. 1A. FIG. 2A differs from FIG. lA
in that portions of outer shell 20 are shown completely separated or detached from each other.
More specifically, top portion 30 is shown offset from, and disposed over, the side portion 40 of the outer shell 20. As a non-limiting example, side portion 40 can comprise a flange or tab 48 that further comprises a number of attachment points 49 configured to interface with, and be coupled to, the top portion 30 of the outer shell 20.

[0038] The attachment points 49, while referred to as points for convenience, need not be points, and can comprise, without limitation, any suitable chemical or mechanical fastener or attachment device or substance including ultrasonic welding (USW), an adhesive, permanent adhesive, pressure sensitive adhesive (PSA), foam-core PSA, tape, two-sided tape, mounting foam adhesive, fastener, clip, cleat, cutout, tab, snap, rivet, hog ring, and hook and loop fasteners that are integrally formed or separately attached to the outer shell 20. The attachment points 49 can be securely, rigidly, or fixedly attached to desired portions of outer shell 20 provided the desired adjustment range of the helmet is not too great. Alternatively, the attachment points 49 can also provide for limited movement, such as with a shear-allowance, for a desired amount of relative movement between portions of the helmet 10 and comprise hook and loop fasteners, foam-core PSA, or other suitable material according to the configuration and design of the helmet 10. In some instances, a first portion or half of an attachment point 49a can be coupled or directly attached to the flange 48, and a corresponding second portion or half of an attachment point 49b can be coupled or directly attached to a portion of the outer shell 20, such as an underside or interior surface 39 of the front piece 35 of the top portion 30.
When the attachment point 49 is an adhesive, the attachment point 49 can cover an entirety or less than an entirety of flange 48. When the attachment point 49 is a mechanical fastener, one, more than one, or a plurality of fasteners can be used. The attachment points 49 can rigidly or moveably coupled any number of portions of the outer shell 20 together, such as the top portion 30 and the side portion 40. Additionally, the attachment points 49 can permanently or releasably couple or affix any number of portions of the outer shell 20 together. In any event, the attachment points 49 can prevent relative movement between the flange 48 of the side portion 40 and the front piece 35 of the top portion 30. Alternatively, as indicated above, the outer shell 20 can comprise a single or unitary integrally formed piece such that the flange 48 of the side portion and the front piece 35 of the top portion 30 of the outer shell 20 can be integrally formed as a single piece. However, by not attaching the top portion 30 to the side portion 40 along an entirety of the interface 50, movement and adjustment of the outer shell 20 to improve sizing and fit to a user's head is possible.

[0039] The outer expansion area 51, along the interface 50, can be filled by one or more flanges or lips 58 formed on the outer shell 20. The lip 58 can be the same or different from flange 48, and can be integrally formed with any portion of the outer shell 20. The lip 58 can also extend around an entirety of the U-shaped interface 52. The flange 58 can provide for an overlap between any number of portions of the outer shell 20, including the top portion 30 and the side portion 40 so that no gap or opening exists along interface 50, from which portions of the user's head can be exposed between the adjustably sized helmet 10. Thus, while in some embodiments the top portion 30 and side portion 40 of the outer shell 20 can be formed of a unitary integrally molded piece, in other embodiments the top portion 30 and side portion 40 can also be formed of separate pieces that allow for overlap of portions of the outer shell 20.

[0040] FIG. 2B shows a perspective view of a portion of the adaptive helmet 10 as seen from below the helmet looking towards an interior of the outer shell 20, the interior of the helmet being configured to receive the user's head. FIG. 2B additionally shows a portion of the helmet 10 with a gap, space, or offset shown between the inner surface 39 of the top portion 30 and the inner surface 89 of the side portion 40. The inner surface 39 of the top portion 30 is formed opposite the outer surface 38 of the top portion 30. Similarly, the inner surface 89 of the side portion 40 is formed opposite the outer surface 88 of the side portion 40. The space, gap, or offset between the top portion 30 and the side portion 40 along interface the interface 50, can be controlled by one or more snap tabs 84. The snap tab 84 can comprise any suitable mechanical fastener or attachment device including rigid or elastic fasteners, stretchable cord, clips, cleats, snaps, hooks, prongs, latches, slots and fasteners, or other device that is integrally formed or separately attached to the outer shell 20. The snap tab 84 can be used for interlocking the top portion 30 and the side portion 40 of the outer shell together with, or independent from, fit system 70. Depending on the configuration and design or the helmet 10, snap tabs 84 can be disposed at any position along the interface 50 or the U-shaped interface 52 to connect and hold together various portions of the helmet 10, including the outer shell 20.

[0041] FIG. 2B also provides additional detail of the snap tabs 84 that can be disposed at, adjacent, or on, the inner surface 39 of the top portion 30 and the inner surface 89 of the side portion 40. Alternatively, snap tabs 84 can be disposed at, adjacent, or on, the outer surface 38 of the top portion 30 and the outer surface 88 of the side portion 40. Additionally, snap tabs 84 can be disposed alternately at, adjacent, or on, both the inner surfaces 39 and 89 as well as at the outer surfaces 38 and 88. The snap tabs 84 can comprise a tab portion 84a and a receiving portion 84b. The tab portion 84a and the receiving portion 84b can be alternately or interchangeably coupled to opposing portions of the outer shell 20. Once coupled, connected, or snapped together, the opposing and mateable tab portion 84a and receiving portion 84b can be permanently or releasably coupled to each other.

[0042] As can be seen in FIG. 2B, the snap tab 84 can be locked together by inserting the tab portion 84a into the receiving portion 84b of the snap tab 84. A
raised portion or ridge on the tab portion 84a can prevent the tab portion 84a from being freely removed from the receiving portion 84b of the snap tab 84. At the same time, snap tab 84 can be configured to allow the side portion 40 and the top portion 30 of the helmet 10 to slide with respect to one another, such as for a length of a tab of the tab portion 84a. By using a snap tab 84, excessive movement between portions of outer shell 20 can be controlled and a desired size of outer expansion area 51 can be maintained. While FIG. 2B shows the tab portion 84a attached to the side portion 40 and the receiving portion 84b attached to the top portion 30, the relative orientation and attachment points of the tab portion 84a and the receiving portion 84a can also be reversed.

[0043] FIG. 3 shows an energy-absorbing material or impact liner 60 disposed within the helmet 10. While not shown, one or more additional layers of comfort padding or a comfort liner can be optionally disposed within the energy-absorbing material.
However, for clarity in presenting features and structures of the energy-absorbing material 60, the comfort liner has been omitted from the figures. Thus, FIG. 3 shows energy-absorbing material 60 can comprise one or more layers of plastic, polymer, foam, or other suitable energy-absorbing material to absorb energy and to contribute to energy management for protecting a wearer during impact. Energy-absorbing material 60 can, without limitation, include EPS, EPU, EPO, EPP, or VN. The energy-absorbing material 60 can be an in-molded layer or can be coupled to the outer shell 20 after molding. In some embodiments, the energy-absorbing material 60 can absorb energy from an impact by being crushed or cracked. As a non-limiting example, the helmet 10 can be formed as a 1-piece in-mold helmet, as a 2-piece in-mold helmet, or as an in-mold comprising any number of pieces. Alternatively, the energy-absorbing material 60 can be made of plastic, polymer, foam, or other suitable energy-absorbing material that can flexibly deform with the outer shell 20 to absorb energy and to contribute to energy management without breaking, cracking, or being crushed. As such, the energy-absorbing material 60 can also be one or more layers of EPP or other similar energy-absorbing and energy-attenuating material that is flexible and able to withstand multiple impacts without being crushed or cracking.

[0044] The energy-absorbing material 60 can be permanently or removably coupled to the outer shell 20 mechanically or chemically with a friction fit, or with a glue, adhesive, permanent adhesive, PSA, foam-core PSA, tape, two-sided tape, mounting foam adhesive, fastener, clip, cleat, cutout, tab, snap, rivet, hog ring or hook and loop fasteners. In order to accommodate the adjustable sizing of helmet 10, the energy-absorbing material 60 can comprise a number of portions or pieces that correspond in number, size, geometry, position, or other feature with portions of the outer shell 20. One or more of the portions of the energy-absorbing material 60 can also comprise ventilation openings 66 to allow for the passage of air from outside the helmet to a wearer's head. The attachment of the energy-absorbing material 60 to the outer shell 20 can be a relatively fixed or rigid attachment, provided the desired adjustment range of the helmet can be accommodated. Alternatively, attachment of the energy-absorbing material 60 to the outer shell 20 can also provide for limited movement, such as with a shear-allowance, for a desired amount of relative movement between the energy-absorbing material 60 to the outer shell 20, so as to accommodate a sizing range and an amount of energy management desired for a particular configuration and design of the helmet 10.

[0045] As a non-limiting example, the energy absorbing material 60 can comprise a top portion 62 coupled to the top portion 30 of the outer shell 20, and a side portion 64 coupled to the side portion 40 of the outer shell 20. In an embodiment, the top portion 62 can be permanently coupled to inner surface 39 of top portion 30 while the side portion 64 can be friction fit to the outer shell 20 and inner surface 89 of side portion 40 without any mechanical fasteners or adhesive. The friction fit of side portion 64 can allow for a floating fit or relative movement of the side portion 64 to accommodate size adjustment of the helmet 10 according to user need and preference while maintaining a desired position of the side portion 64 within the helmet base on the geometry and tapered curvature of the outer shell 20.
Similarly, even those portions of the energy-absorbing layer 60 that are permanently coupled to portions of the outer shell 20 can be coupled in such a way as to allow for movement of the energy-absorbing layer 60 with the outer shell 20 when providing an adaptive fit so that a contour of an inner surface of the helmet 10, such as an inner surface of the energy-absorbing layer 60, matches or conforms to a contour of the wearer's head. As a non-limiting example, the inner surface of the helmet 10, such as the inner surface of the energy-absorbing layer 60, can be made narrower, wider, shorter, longer, rounded, or squarish, to match and follow a contour of a wearer's head, whether the helmet 10 is tapered or not.

[0046] In some embodiments, the energy management material 60 can not only move or flex within the outer shell 20 to accommodate sizing adjustments and match or conform to a user's head, but the energy management material 60 can also flex with outer shell 20 to provide improved or increased energy management. In some embodiments, movement and flex of the helmet 10 can be controlled at least in part by the geometry of the energy management material 60. The energy management material 60 can be formed comprising an alligator panel of foam, comprising separate cells or sections like a honeycomb, or comprising an egg carton like arrangement comprising alternating high and low portions. The energy management material 60 can comprise ridges and voids so that less than an entirety of the surface of the energy-absorbing material 60 is in contact with the outer shell 20. As such, an entirety of the energy-absorbing material 60 is not directly attached to the inner surface 39 and the inner surface 89 of the outer shell 20. As such, forming the energy-absorbing material 60 comprising an uneven surface can facilitate and allow for bending of the outer shell 20 with less stress on an interface or attachment between the energy-absorbing material 60 and the outer shell 20. Furthermore, when the energy management material 60 comprises separate cells or a honeycomb design, the cells can individually deform or be crushed in absorbing impact energy.

[0047] As shown in FIG. 3, an interface edge 63 can be formed or disposed at an outer edge of the top portion 62, and an interface edge 65 can be formed or disposed at an inner edge of the side portion 64 along the inner expansion area 61. Thus, the inner expansion area 61 can be exist between, and be defined by, the interface edge 63 and the interface edge 65. As shown in FIG. 3, the interface edges 63 and 65 can comprise smooth continuous curved edges that mirror, match, or are mateably configured one to another. As such, when a size of the helmet 10 is adjusted, the curved interface edge 62 and the curved interface edge 65 allow for 3-dimensional adjustment, both expansion and contraction, of the outer shell 20 and of the inner expansion area 61.

[0048] As used herein, the expansion and contraction of the size of the helmet 10 including the size the outer shell 20 and of the size of inner expansion area 61 can include a volume of the outer shell 20 and of the inner expansion area 61, or stated another way, the volume included within the inner surfaces of the outer shell 20 and of the inner expansion area 61. The 3-dimensional adjustment can occur between the temple alignment 82 and a rear or the helmet 10, such as at the outer surface 38 of the outer shell 20 over the fit system mechanism 74.
As shown in the figures, temple alignment 82 can designate a temple area of the helmet 10 that sits over a temple of a user when the user is wearing the helmet. Stated another way, a temple area of the helmet 10 can be an area that is toward a front of the helmet and is in front of a ear opening 80 or cut-out for a user's ear. Conventional helmet designs that have facilitated 2-dimentional sizing have included manipulation of an outer shell at an area behind a user's ears, or between an area of the helmet between the rear of the helmet and the user's ears without manipulating or adjusting a size of the helmet in an area between the front of the helmet and the users ears as can be done with helmet 10. Stated another way, convention helmet designs facilitating 2-dimensional sizing have allowed for sizing adjustments at the rear or tail portion of the helmet only, such as at a position of rear tapered interface portion 36 in helmet 10.

[0049] Conventional helmet designs that have facilitated 2-dimentional sizing have included energy absorbing materials that has comprised wavy or interlocking edges. By forming interface edge 63 and interface edge 65 without wavy interlocking edges, and selecting instead smooth continuous curved edges, the interface edges can be U-shaped to follow the U-shaped interface 52 or an outer expansion area 51 of the interface 50 between the top portion 30 and the side portion 40 of outer shell 20. Thus, the U-shape of inner expansion area 61 without wavy or interlocking edges, as well as the optional floating design of side portion 64 together with the uncoupled design of the outer shell behind the temple alignment can allow for 3-dimensional adjustment of the helmet 10, including simultaneous adjustment of the width W
and the length L
of the helmet 10, including simultaneous adjustment along a 3-dimensional vector comprising component of both the helmet width W and the helmet height H.

[0050] Thus, the helmet 10 can contribute to energy management in at least two ways. First, the energy-absorbing material 60 can absorb material through deformation. Second, the outer shell 20 of the helmet 10 can absorb energy by flexing or deforming to absorb energy from an impact. With respect to energy management by the outer shell 20, an amount of energy managed through flexing of the outer shell 20 can be, at least in part, a result of the material used for the outer shell 20 as well as a result of the geometry of the outer shell 20. In some embodiments, energy management through flexing of outer shell 20 is controlled by both the material and geometry of the outer shell 20. In contrast to other conventional adjustable helmets known in the prior art, such as the hockey helmets, significant energy management is not provided through flexing of the outer shell, including instead rigid helmet shells that slide with respect to each other for sizing, and then once sized, remain with fixed relative positions without flexing. As such, the hinged design of the helmet 10, including an outer expansion area 51 that allows for flexing and movement of the outer shell 20 and relative movement of energy-absorbing material 60 provides improved energy management with respect to previous helmet designs known in the art.

[0051] Furthermore, the design of the helmet 10 can allow for a flexible design comprising materials conventionally considered and used for rigid non-flexible designs and not for flexible designs. More specifically, the flexible design of the helmet 10 can optionally comprise the features of forming the energy-absorbing material 60 with separate top and side portions, a U-shaped geometry of portions of the helmet 10, and a floating fit of at least a portion of the energy-absorbing material 60. The adaptive design of the helmet 10 can also comprise the energy-absorbing material 60 comprising materials such as EPS, EPU, and EPO, which are materials that have been conventionally considered rigid materials for helmet applications without flexing, being used instead for applications in which energy management and energy-absorption is provided by the material being destroyed through cracking, crushing, or crumpling, and not through flexing.

[0052] FIGs. 4A and 4B show fit system 70 for helmet 10 that can adjust a size, shape, or both of the helmet 10 to allow for a better fit to a user's head, an improved overall helmet shape, and flexing of the helmet 10 for improved energy management. Fit system 70 can be disposed within helmet 10, such as within or inside an outer surface of the helmet 10 or at an interior of the helmet 10. In some instances, fit system 70 can be formed inside out with respect to helmets that have fit systems on an outer surface of the helmets, and can further be disposed between outer shell 20 and energy management material 60 so as to be at least partially hidden from view of a user. For ease of illustration, portions of helmet 10 are shown as being transparent in FIGs. 4A and 4B to enable visualization of the fit system 70.

[0053] FIG. 4A shows a perspective view of the rear and left sides of the helmet 10, similar to the view shown in FIG. 1B. FIG. 4A further shows that the fit system 70 can comprise one or more belts, cables, cords, ratchet bindings, rods, arms, cranks, cams, or other suitable devices 72. Fit system 70 can also include a fit system mechanism or sizing mechanism 74. Fit system mechanism 74 can comprise a dial, rack, knob, lever, switch, toggle, key, ratcheting lock, or other suitable device that can adjust a length of the belt 72. Taken together, the belt 72 and fit system mechanism 74 of the fit system 70 can adjust a size and fit of the helmet 10 for a user of the helmet. As non-limiting examples, fit system 70 can comprise belt 72 configured as a rack and fit system mechanism 74 configured as a pinion, while as another example, belt 72 can be configured as a cable and fit system mechanism 74 can be configured as a wheel. In either instance a gear ratio of 1:1 can be used between belt 72 and fit system mechanism 74, or alternatively, a gear reduction or gear increase can be used to modify the gear ration to any desired proportion, such as 1:2, 2:1, 1:3, 3:1, 1:4, 4:1, 1:5, 5:1, or any other desirable ratio.

[0054] FIG. 4A also shows that the fit system mechanism 74 can be coupled to both belt 72 and outer shell 20. The fit system mechanism 74 can be coupled to, and disposed through, outer shell 20 to provide convenient user access for adjusting fit system mechanism 74.
FIG. 4A shows a non-limiting example of a fit system mechanism 74 can be disposed through rear tapered interface portion 36 near lower exterior edge 22 of outer shell 20. In some embodiments, fit system mechanism 74 can be partially covered by a portion of outer shell 20, or conversely, can be partially or completely exposed with respect to the outer shell 20.
Alternatively, the fit system mechanism 74 can be coupled to a side portion of the helmet 20 or to any other portion of the helmet 10.

[0055] The fit system 70 can comprise one or more belts 72 according to a configuration and design of the helmet 10. In configurations of helmet 10 comprising three portions at the rear of the helmet, such as a rear tapered interface portion 36 of the top portion 30 and two adjacent opposing side portions of side portion 40, two or belt segments can be desirable. The two belt segments can be two separate or discrete belts 72.
Alternatively, the two belt segments can be two portions or segments of a longer single long belt 72.
FIG. 4A shows belt 72 comprising a first attachment point or end 72a offset or opposite from second attachment point or end 72b. The first attachment point 72a of the belt 72 can be coupled or directly mounted to an anchor or attachment point 76 on the outer shell 20. The attachment point 76 can be any suitable chemical or mechanical fastener including an adhesive, clip, cleat, cutout, grommet, or rivet, that is integrally formed or separately attached to the outer shell 20. The second attachment point or end 72b of belt 72 can be further coupled or directly mounted to the fit system mechanism 74. As the fit system mechanism 74 is moved, twisted, or otherwise adjusted, the one or more belts 72 can also be adjusted, such as being shortened, lengthened, or repositioned such that at least one belt can push or pull portions of outer shell 20, such as the top portion 30 and the side portion 40 of the outer shell 20 together to increase or decrease a size, shape, or both, of the helmet 10 to better fit a head of the user. Thus, by using the fit system 70 to adjust the outer shell 20, and corresponding portions of energy management material 60, the tightening or loosening of the helmet 10 can adjust a size, shape, or both, of the helmet 10 in multiple directions simultaneously, such as in a side-to-side direction and a front-to-back direction. In some instances, additional guidance members in the form or tracks, sleeves, rods, channels, lines, cords, or other suitable device can also be used in maintaining a desired alignment or relative position of various portions of outer shell 20 during adjustment of helmet by fit system 70.

[0056] When adjusting a size of helmet 10 with fit system 70, a size of the outer expansion area 51 can be proportionally adjusted. As such, a width of the lip 58 at the interface of the top portion 30 and the side portion 40 of the outer shell 20 can correspond to an amount of adjustment that can be made to increase or decrease a size of the adaptive helmet when conforming to a size or shape of a user's head. As shown in FIG. 4A, outer expansion area 51 can be filled with a lip 58 of outer shell 20 that fills with interface area 50. Lip 58 can be part of any portion of outer shell 20, and in some embodiments can be part of top portion 30 or side portion 40 that extends beyond one or more of: longitudinal portion edge 34, rear tapered interface edges 37, longitudinal portion edge 44, or rear tapered interface edges 47. As such, overlap of outer shell 20 can be provided so as to reduce exposure to a head of a user and to increase coverage and protection of the user's head. In other embodiments, such as shown in FIG. 5A, the outer expansion area 51 can be formed without lip 58 to provide an opening or gap between portions of the outer shell 20, such as to provide additional ventilation. In yet other embodiments, a size of lip 58 can be occupy a portion of outer expansion area 51 that is less than an entirety of the outer expansion area 51 to provide for both additional protection and ventilation.

[0057] FIG. 4B shows a plan or top view of a rear portion of the underside or inside surface of the helmet 10, similar to the view shown in FIG. 3. FIG. 4B
provides additional detail of how portions of energy management layer 60 can be positioned or arranged on an inner surface of outer shell 20. FIG. 4B also provides additional detail relating to how the fit system 70 can be used to adjust a relative position of the top portion 30 and side portion 40 of the outer shell 20, and their accompanying segments of energy management layer 60, to adaptively fit the helmet 10 to a size, shape, or both, of the user's head.

[0058] As further shown in FIG. 4B, the first attachment point 72a and the second attachment point 72b of one or more belts 72 can be coupled to anchors 76 on the side portion 40 of the outer shell 20. Portions of the one or more belts 72 can also be coupled to fit system mechanism 74. For symmetrical or equidistantly spaced elements, such as belts 72, fit system mechanism 74, and anchors 76, as the fit system mechanism 74 is moved, a length, position, or both of the belts can be equally changed to equally adjust the relative positions of the top portion 30 and the side portion 40 of the outer shell 20 to tighten or loosen the helmet 10 in a side-to-side direction, a front-to-back direction, or both. In another embodiment, non-equal spacing or arrangements can result in non-equal or unevenly divided movement or positioning, which could be desirable for particular configurations, arrangements, or geometries of the helmet 10.

[0059] The fit system 70 can allow for helmet 10 to be an adaptive one-size-fits-all or one-size-fits-most helmet where both energy-absorbing material 60 and the outer shell 20 can be adjustably fit to a size, shape, or both, to a user's head. Accordingly, use of fit system 70 can adjust a size of outer expansion area 51 and inner expansion area 61. A size of expansion areas 51 and 61 can be at a maximum width or offset when fit system 70 or helmet 10 is at its largest or widest setting. Conversely, a size of expansion areas 51 and 61 can be at a minimum width or offset when fit system 70 or helmet 10 is at its smallest or narrowest setting. When fit system 70 or helmet 10 is at its smallest or narrowest setting, a size of expansion areas 51 and 61 can be can be reduced to zero so that adjacent pieces or edges of outer shell 20 and energy-absorbing material 60 are touching or in contact with each other. As such, the fit system 70 can advantageously adjust both the outer shell 20 and the energy-absorbing liner

60 to provide for an improved adjustable fit, increased protection, or both, with respect to conventional helmets that comprise fit systems that adjust only an outer shell.
[0060] When the belt 72 is formed as a rack, and the fit system mechanism 74 is configured as a pinion, the rack and pinion configuration can allow for dual purpose size adjustment by both pushing and pulling portions of outer shell 20 to be to increase or decrease, respectively, a size of the helmet 10. Thus, the dual purpose sizing enabled by the rack and pinion configuration of belt 72 and fit system mechanism 74 can provide increased functionality with respect to conventional designs that use a cable and can only tighten or decrease a size of the helmet. Furthermore, the fit system 70, including belt 72 and the fit system mechanism 74, whether formed as a rack and pinion or not, can be disposed between the outer shell 20 and the energy-absorbing material 60. By disposing the fit system 70 between the outer shell 20 and the energy-absorbing material 60, the fit system is substantially entirely hidden from view as shown in FIG. 3, with only a portion of the fit system mechanism 74 exposed. The hidden position of the fit system 70 differs from conventional designs using cables disposed at an exterior of the helmet because the conventional fit systems disposed at an exterior of the helmet can induce additional rotation of helmet components, unlike the hidden design of the fit system 70.

[0061] FIGs. 5A and 5B show profile or side views of a rear portion of helmet. In FIG. 5A, helmet 10 is shown in a condition in which fit system 70 has increased a size of the helmet 10 to a large or maximum size. In FIG. 5B, helmet 10 is shown in a condition in which the fit system 70 has reduced a size of the helmet 10 to a small or minimum size. In both FIGs.

5A and 5B, a non-limiting example of a helmet 10 comprising three moving sections is shown.
The three moving sections include: (1) the rear interface tapered portion 36 of top portion 30 of outer shell 20, (2) the left rear tapered interface portion 461, and (3) the right rear tapered interface portion 46r.

[0062] In FIG. 5A, when the helmet 10 is at its large or open position, a width 50w of interface 50 can vary as it extends along the helmet 10 from the lateral portions 53 of the U-shaped interface 52 to the rear tapered interface 56 terminating at lower exterior edge 22. The width 50w of interface 50 can vary from a small or no width to a large or maximum width. No width, or a width of zero for the width 50w of interface 50 can occur when the longitudinal edges 44 of side portion 40 contact the longitudinal edges 34 of top portion 30. The large or maximum width of the width 50w of interface 50 can vary based on the geometry and configuration of outer shell 20, including the shape of interface 50 and the fit system 70 to accommodate users of multiple differing head sizes and multiple differing head shapes. As a non-limiting example, in some embodiments the large or maximum width of the width 50w of interface 50 (or half the width of a total width of expansion or contraction of the helmet 10) can be less than or equal to 5.0 centimeters (cm), 4.0 cm, 3.0 cm, 2.5 cm, 2.0 cm, or less, for each interface 50, such as the interfaces 50 on the left rear tapered edge 471 and the right rear tapered edge 47r.

[0063] In FIG. 5B, when the helmet 10 is at its small or closed position, a width 50w of interface 50 can be constant or comprise little variation as it extends along the helmet 10 from the lateral portions 53 of the U-shaped interface 52 to the rear tapered interface 56 terminating at lower exterior edge 22. When helmet 10 is in a closed position, the width 50w of interface 50 can comprise zero or no width, such as when longitudinal edges 44 of side portion 40 contact the longitudinal edges 34 of top portion 30. The small or minimum width of the width 50w of interface 50 can vary based on the geometry and configuration of outer shell 20, including the shape of interface 50 and the fit system 70 to accommodate users of multiple differing head sizes and multiple differing head shapes. As a non-limiting example, in some embodiments the small or minimum width 50w can vary based on the geometry and configuration of outer shell 20, including the shape of interface 50 and the fit system 70, and can be less than or equal to 1.0 cm, 0.5 cm, 0.25 cm, or less for each interface 50, such as the interfaces 50 on the left rear tapered edge 471 and the right rear tapered edge 47r.

[0064] A shape of the interface 50 between various components of the outer shell 20, such as a shape of the interface between the top portion 30 and the side portion 40 can allow for angular adjustment or adjustment along a vector in 3 dimensions rather than movement in two directional space as done previously by conventional helmets, such as some hockey helmets. For example, USP 8,510,870 to Rogers et al. (hereinafter "Rogers") as well as US
Pub.
2014/0259315 to Durocher et al. (hereinafter "Durocher") show movement in two directions, such as along a length to increase or decrease a distance front to back of the helmet, or such as across a width of the helmet to increase or decrease a distance from side to side of the helmet.
Previously, adjustments of helmets, such as those show in Rogers and Durocher, were adjusted in two distinct steps, or by two distinct mechanisms, separately adjusting both a length and width. To the contrary, helmet 10 including outer shell 20, can simultaneously adjust for both length and width together, and at a same time, due to the geometry of the interface of the top portion 30 and the side portion 40 and due to fit system 70 exerting force along a 3-dimensional (3D) vector.

[0065] Furthermore, the benefits of 3D adjustment, angular adjustment, or adjustment along a vector in 3 dimensions of the helmet 10 are not limited to quickly and efficiently adjusting both length and width together of the helmet 10 together. Instead, benefits of the 3D
adjustment of the helmet 10 also include an improved adaptive fit of the helmet 10 to the head of the user. More specifically, the flexible nature of both the outer shell 20 and the energy-absorbing material 60 can allow for the shape and contours of the user's head.
For example, when the fit system is open and a user places the helmet 10 over his head, heterogeneous or non-uniform offsets or gaps can exist between the inner surface of the helmet 10 and the user's head.
As the fit system 70 is employed to decrease a size of the helmet 10 and the volume of the space contained within the helmet 10, the voids and spaces between the inner surface of the helmet 10 and the user's head also decrease. However, the gaps and offsets between the inner surface of the helmet 10 and the user's head are not limited to being reduced uniformly, at an equal rate, or both, so that portions of the energy-absorbing material 60 contact a user's head, while other do not. Instead, the flexibility of the helmet 10 can allow for one or more of a shape, a size, or one or more contours of the helmet to change to match one or more of a shape, a size, or one or more contour of the user's head. For example, when engaging fit system 70 to reduce a size of the helmet 10, a first portion of the inner surface of the helmet 10 contacting the user's head can act as a pivot point or fulcrum around which the shrinking volume of the helmet will be drawn inward toward, and form itself to, the user's head. As such, the conforming and adaptive fit of the helmet 10 provides a number of benefits, which without limitation can include the following.
First, an amount of surface area of the user's head that is in contact with an amount of surface area of the inner surface of the helmet 10 can be increased. Second a size or volume of the gaps, offsets, and voids between the surface of the user's head and the inner surface of the helmet 10 can be decreased. Third, by forming a shape and contour of an inner surface of the helmet 10 to match a shape, size, and contour of the user's head, pressure points or small areas, points, or ridges between uneven portions of the user's head an the inner surface of the helmet 10 will be reduced, thereby increasing safety and performance of the helmet 10.

[0066] Thus, while benefits of an increased taper and a more streamlined look are accomplished, such as is discussed below in greater detail, the helmet sizing is not limited to the helmet matching a lateral taper or slope of the user's head. Instead, all surfaces of the helmet 10, both inner and outer, can follow a form or contour of the user's head. As a non-limiting example, the inner surface of the helmet 10, such as the inner surface of the energy-absorbing layer 60, can be made narrower, wider, shorter, longer, rounded, or squarish, to match and follow a contour of a wearer's head, whether the helmet 10 is tapered or not. As such, while the discussion below is, for convenience, discussed in relation to rear views of the helmet 10, the same principles and discussion are also applicable to other dimension and portions of the helmet, such as rear tapered interface portion 36 that can also be drawn towards and conform with a back portion of the user's head, including the occipital curve.

[0067] FIGs. 5A and 5B also provide a comparison between a width Wb that extends between back bottom corners 86 of the helmet 10 and an overall or maximum width W of the helmet 10, which can be represented by a ration of Wb:W or taper ratio. While the taper ratio can be used as a convenient measure or point of reference for the helmet 10 while the helmet is not worn, as described above, a shape of the helmet 10 can, when worn, have its shape interactively changed to match a contour of the user's head. As indicated above, the width Wb of the helmet 10 can be measured between back bottom corners 86 of the helmet 10. For convenience, and not by way of limitation, back bottom corners 86 can refer to the lowest points on the lower exterior edge 22, or in other words, those points at which the helmet will rest or make contact on a level planar surface. Stated another way, the back bottom corners 86 can be the points of inflection at the lower exterior edge 22 at which the downward taper from the overall width W to the width between the bottom back corners Wb. As shown in FIGs. 5A and 5B, a taper ratio of Wb:W in the open position shown in FIG. 5A can be larger than a ratio of Wb:W in the closed position shown in FIG. 5B. As a non-limiting example, a taper ratio of the helmet 10 in an open position can be about 4.75:8.3 or 0.57, and a taper ratio helmet 10 in a closed position can be about 3.75:7.75 or 0.48. As such, a percent difference in the taper ratio between the open and closed positions can be (0.57-0.48)/0.57 or about 16%. As used herein, about can include a difference of plus or minus 3% or less. A percent difference between the open and closed taper ratios for helmet 10 can also be in a range of about 10-30%. Furthermore, the taper ratio of the helmet 10 in a closed position can be in a range of about 30-60% or about 30-45%.

[0068] As shown in FIGs. 5A and 5B, the above described taper ratios and decreased width Wb present a slimmer, sleeker form than is present with the bloated and inflated look of conventional designs that do not provide 3-dimensional adjustment to taper around and match a curve of a wearer's occipital curve. Accordingly, helmet 10 can be adjusted to a specific user so that a size, shape, or both, of the helmet 10 does not look disproportionately large with respect to the wearer's body, as was sometimes the case with helmets in the prior art.
Instead, the outer surface 88 of side portion 40 tapers in to match a taper or curve from a wearer's head down to the wearer's neck. The form fitting adjustment of the helmet 10, in addition to providing an improved aesthetic, can also provide a better fit, which can result in improved crash performance and greater safety. Conventionally, a bottom opening in a helmet has to be large enough to allow the largest portion of the wearer's head to enter the opening. However, the fit system 70 and the adaptive fit of the helmet 10 can allow the opening of the helmet 10 to be made smaller while still allowing a user to put on the helmet. Thus, the improved fit of the helmet 10 can allow for a closer match between a shape of the helmet and a shape or contour of the user's head to provide improved protection while accommodating different head sizes and head types, such as narrow heads and wide heads, for a variety of users.

[0069] FIG. 6 shows a plan or top view of the helmet 10 with a front of the helmet 10 disposed at a top of the figure. A number of vents or ventilation openings 90 can be formed in and through outer shell 20, including through top portion 30 and side portion 40. Vents 90 can correspond to, and align with, ventilation openings 66 in energy-absorbing material 60 so as to allow air to freely circulate between outside the helmet 10 and the user's head. A size of the vents 90 can comprise a minimum size large enough to permit a desirable amount of airflow.
The size of the vents 90 can also comprise a maximum size small enough to prevent foreign objects from pushing through or puncturing the helmet to contact a wearer's head. In some instances, the maximum size of the vents 90 will be determined by a relevant safety standard, requirement, or regulation. A position of one or more of the vents 90 can be positioned according to the configuration and design of the helmet 10 to accommodate aerodynamics, ventilation, or other purposes as desired.

[0070] Vents 90 can also comprise covers or ventilation opening covers 92 that can be retractably disposed within the vents 90. The covers 92 can be formed of plastic, such as a thermoplastic, or other suitable material, and in some instances can be made of a material that is similar or identical to outer shell 20. Retraction and positioning of the covers 92 can be controlled by a switch or vent switch 94. The vent switch 94 can be positioned at any position on an exterior or interior of the helmet, and as shown in FIG. 6, can be conveniently positioned at a top or crown portion of the helmet. The vent switch 94 can be coupled to one or more the covers 92, including a totality of the covers 92, to simultaneously move the covers 92 between open and closed positions. While the vent covers 92 can completely cover the vents 90, the vent covers 92 can also partially cover the vents 90, or can cover none of the vents 90. When the covers 92 are not covering any of the vents 90, the covers 92 can be disposed adjacent the vents 90 between the outer shell 20 and the energy absorbing material 60.

[0071] Where the above examples, embodiments and implementations reference examples, it should be understood by those of ordinary skill in the art that other helmet and manufacturing devices and examples could be intermixed or substituted with those provided. In places where the description above refers to particular embodiments of helmets and customization methods, it should be readily apparent that a number of modifications may be made without departing from the spirit thereof and that these embodiments and implementations may be applied to other to helmet customization technologies as well.
Accordingly, the disclosed subject matter is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the disclosure and the knowledge of one of ordinary skill in the art.

Claims

What is claimed is:

1. An adaptive fit helmet, comprising:
an outer shell comprising a top portion, a side portion, and an outer expansion area that extends along an interface of the top portion and the side portion from a temple area of the outer shell to a lower exterior edge of the outer shell;
an energy-absorbing material disposed within the outer shell, wherein the energy-absorbing material further comprises a top portion, a side portion, and an inner expansion area between edges of the top portion and the side portion of the energy-absorbing material such that the inner expansion area corresponds with the outer expansion area; and a fit system comprising a belt coupled to the side portion of the outer shell and a fit system mechanism coupled to the top portion of the outer shell, wherein a position of the fit system controls both a three-dimensional size and shape of the outer shell as well as a three-dimensional size and shape of the energy-absorbing material.

2. The adaptive fit helmet of claim 1, wherein the belt of the fit system comprises a rack and the fit system mechanism comprises a pinion such that the rack and pinion are configured to both push and pull the top portion and the side portion of the outer shell to either increase or decrease the three-dimensional size and shape of both the outer shell and the energy-absorbing material.

3. The adaptive fit helmet of claim 1, wherein the outer shell comprises a flexible outer shell and the energy-absorbing material comprises expanded polystyrene (EPS), expanded polyurethane (EPU or EPTU), expanded polyolefin (EPO), expanded polypropylene (EPP), or vinyl nitrile (VN).

4. The adaptive fit helmet of claim 1, wherein the fit system controls the three-dimensional size and shape of the outer shell between the temple area and an ear area of the outer shell.

5. The adaptive fit helmet of claim 1, wherein the interface of the top portion and the side portion the outer shell comprises a U-shape and the inner expansion area of the energy-absorbing material also comprises a U-shape.

6. The adaptive fit helmet of claim 1, wherein the top portion of the outer shell and the side portion of the outer shell are formed as two discrete portions, and the top portion of the outer shell and the side portion of the outer shell are coupled to each other.

7. A method of using the adaptive fit helmet of claim 1, comprising adjusting the fit system so that a flexibility of the adaptive fit helmet allows for a size, a shape, and a contour of the adaptive fit helmet to change to match a shape, a size, and a contour of a head of a user.

8. An adaptive fit helmet, comprising:
an outer shell comprising an outer expansion area that extends from a temple area of the outer shell to a lower exterior edge of the outer shell;
an energy-absorbing material disposed within the outer shell; and a fit system comprising a belt coupled to the outer shell and a fit system mechanism coupled to the outer shell and the belt, wherein a position of the fit system controls a three-dimensional size and shape of the outer shell.

9. The adaptive fit helmet of claim 8, wherein the belt of the fit system comprises a rack and the fit system mechanism comprises a pinion such that the rack and pinion are configured to both push and pull the outer shell to either increase or decrease the three-dimensional size and shape of the outer shell.

10. The adaptive fit helmet of claim 8, wherein the outer shell comprises a flexible outer shell and the energy-absorbing material comprises expanded polystyrene (EPS), expanded polyurethane (EPU or EPTU), expanded polyolefin (EPO), expanded polypropylene (EPP), or vinyl nitrile (VN).

11. The adaptive fit helmet of claim 8, wherein the fit system controls the three-dimensional size and shape of the outer shell in front of an ear opening of the outer shell.

12. The adaptive fit helmet of claim 8, wherein the helmet tapers in towards back bottom corners of the lower exterior edge of the outer shell so that a taper ratio of a width between the back bottom corners to a width of the helmet (Wb:W) for the adaptive fit helmet in an open position is larger than a taper ratio Wb:W for the adaptive fit helmet in the closed position.

13. The adaptive fit helmet of claim 8, wherein the position of the fit system is configured to control both a two-dimension length and two-dimensional width of the outer shell simultaneously and to cause the outer shell to flex.

14. An adaptive fit helmet, comprising:
an outer shell comprising an outer expansion area that extends along the outer shell to a lower exterior edge of the outer shell;
an energy-absorbing material disposed within the outer shell, wherein the energy-absorbing material further comprises an inner expansion area corresponds with the outer expansion area; and a fit system comprising a belt coupled to the outer shell and a fit system mechanism coupled to the outer shell and the belt, wherein a position of the fit system simultaneously controls both a size and shape of the outer shell as well as a size and shape of the energy-absorbing material.

15. The adaptive fit helmet of claim 14, wherein the belt of the fit system comprises a rack and the fit system mechanism comprises a pinion such that the rack and pinion are configured to alternately push and pull the outer shell to either simultaneously increase or decrease the size and shape of the outer shell as well as the size and shape of the energy-absorbing material.

16. The adaptive fit helmet of claim 14, wherein the outer shell comprises a flexible outer shell and the energy-absorbing material comprises expanded polystyrene (EPS), expanded polyurethane (EPU or EPTU), expanded polyolefin (EPO), expanded polypropylene (EPP), or vinyl nitrile (VN).

17. The adaptive fit helmet of claim 14, wherein the fit system controls the size and shape of the outer shell and the energy-absorbing layer in an area of the adaptive fit helmet between a temple area and an ear area of the adaptive fit helmet.

18. The adaptive fit helmet of claim 14, wherein the inner expansion area comprises a U-shape.

19. The adaptive fit helmet of claim 14, wherein the outer shell comprises two discrete portions that are coupled to each other at a flange away from the outer expansion area.

20. A method of using the adaptive fit helmet of claim 14, comprising adjusting the fit system so that a flexibility of the adaptive fit helmet allows for a size, a shape, and a contour of the adaptive fit helmet to change to match a shape, a size, and a contour of a head of a user.