CA3224657A1 - Impact protection system - Google Patents

Abstract

Disclosed is an impact protection system for wearing on a head of a user. The impact protection system has a protective layer formed from a plurality of panels. At least one of the panels can translate relative to one or more of the other panels a sufficient amount to facilitate a change in the shape of the protective layer. Such a system may be advantageous by allowing the impact protection system to accommodate a variety of head shapes and sizes. This in turn makes the system more comfortable for the user, as well as potentially making a single design and/or size suitable for a wider range of users.

Description

IMPACT PROTECTION SYSTEM
Background of the Invention [0001] The present invention relates broadly to an impact protection system and in one example to a wearable impact protection system, such as a helmet.
Description of the Prior Art

[0002] The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that the prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

[0003] It is known to provide impact protection systems, such as helmets.
Traditional helmets include a rigid outer shell overlaying a deformable material. When struck by an object, the other rigid shell tends to dissipate forces, and prevent penetration by the object, whilst the deformable material acts to absorb the forces. Whilst such systems can provide a high degree of protection, they tend to be heavy, unwieldly and difficult to transport, as well as being uncomfortable to wear for physical activities, such as cycling, skiing, snowboarding or the like.

[0004] A number of attempts have been made to address such deficiencies. For example, US

5,661,854 describes a flexible helmet with an outer layer of impact resistant segments and an inner layer of energy absorbent structures. The segments are connected by flexible elastic panels and an annular crown structure. While enabling a helmet with at least some degree of flexibility, the helmet can allow gaps between the impact resistant segments, thereby having the potential to allow penetration by a sharp object in these locations.
[0005] US 7,207,072 describes a helmet with movable parts to alternate between forms of protection. While a chin guard and a visor are movable, the main portion of the helmet covering the side, top and back of the head is largely fixed in size and/or shape.

[0006] WO 2019/076689 describes a helmet with an outer shell and an inner shell, where the inner shell is able to slide relative to the outer shell. The inner shell is also made in segments, so that the segments can slide relative to the outer shell somewhat independently of one another.
Such a design is designed to protect the user from tangential components of impact as well as from radial impact. However, the outer shell does not allow for flexibility of the helmet shape.

[0007] US 2015/0320134 describes a lightweight protective headgear for non-contact sports comprising a soft foam helmet designed to prevent head and facial injuries to the user. Whilst this is lightweight and flexible, this provides minimal protection and is therefore not suitable for many applications.
Summary of the Present Invention

[0008] According to one aspect of the invention, there is provided an impact protection system for wearing on a head of a user, the impact protection system comprising a protective layer formed from a plurality of panels, wherein at least one of the panels can translate relative to one or more of the other panels a sufficient amount to facilitate a change in the shape of the protective layer.

[0009] In an embodiment, the panels are flexible.

[0010] In an embodiment, at least some of the panels that are adjacent partially overlap.

[0011] In an embodiment, the overlapping of the panels comprises a half lap join.

[0012] In an embodiment, one of the panels comprises a notch and another one of the panels comprises a tab, such that the tab fits within the notch to locate the panels in a neutral position.

[0013] In an embodiment, the impact protection system further comprises a deformable layer inside the protective layer so as to face a wearer in use.

[0014] In an embodiment, the deformable layer comprises a shear thickening or non-Newtonian component.

[0015] In an embodiment, the deformable layer comprises at least one of: a shear thickening foam; a shear thickening moulded foam; a polymer matrix comprising a shear thickening additive; a foam with non-Newtonian fluid filling; a non-Newtonian material; a polyurethane energy-absorbing material; and, a polyurethane material containing Polyborodimethylsiloxane.

100161 In an embodiment, the shear thickening or non-Newtonian component has a thickness that is at least one of: ¨5mm; <5mm; <20mm; >10mm; 5-20mm; 10-15mm; <30mm;
and, ¨30mm;
[0017] In an embodiment, the deformable layer is made of at least one of: an auxetic material;
a deformable fluid layer; an impact absorbing foam; an elastically deformable layer; a plastically deformable layer; a plastic; a rubber; Kevlar; an EPU (Expanded PolyUrethane) foam; an EPS (Expanded Polystyrene) foam; an EPP (Expanded Polypropylene) foam; and, a PPS (Polyphenylene Sulfide) foam.
[0018] In an embodiment, the deformable layer and the protective layer are at least partially coupled using at least one of: mechanical bonding; chemical bonding; welding;
adhesive; and, fasteners.
[0019] In an embodiment, the deformable layer is removable.
[0020] In an embodiment, the deformable layer has a thickness that is at least one of: ¨15mm;
>20mm; >23mm; <26mm; <30mm; 20-25mm; 23-26mm; and, ¨30mm; and, the protective layer has a thickness that is at least one of: ¨1mm; >lmm; >1.5mm; <3mm; <4mm;
1-4mm;
1.5-3mm; and, ¨4mm.
[0021] In an embodiment, the deformable layer comprises a plurality of sections that are each attached to a single one of the panels.
[0022] In an embodiment, the plurality of sections of the deformable layer comprise chamfered edges to accommodate the translation of the panels.
[0023] In an embodiment, a flexible member extends downwardly from a lower edge of a rear portion of the deformable layer.
[0024] In an embodiment, the flexible member is configured to abut and substantially conform to a shape of a user's head and/or neck during use.
[0025] In an embodiment, the deformable layer has a cover extending over an inner surface so as to be located between the deformable layer and the head of the user during use, the cover being made of at least one of: a woven fabric; a non-woven fabric; an elasticated fabric; and, an open cell foam.
[0026] In an embodiment, the protective layer has a cover extending over an outer surface, the cover being made of at least one of: a woven fabric; a non-woven fabric; an elasticated fabric;
and, an open cell foam.
[0027] In an embodiment, the panels are connected to one another to limit a width of a gap that can form when adjacent panels translate away from one another.
[0028] In an embodiment, the panels are connected by at least one of: an elastic tether; an inelastic strap; a flexible band; and, a rigid brace.
[0029] In an embodiment, the protective layer comprises at least one backing member that spans the gap caused when the panels translate away from one another.
[0030] In an embodiment, the backing member comprises at least one groove and the panels on either side of the backing member comprise at least one pin that extends into the groove, the pins and groove thereby cooperating to allow but also limit relative translation between the panels that are connected by the backing member.
[0031] In an embodiment, the relative translation between the panels can occur in three dimensions.
[0032] In an embodiment, one of the panels is a central spine that is flexible.
[0033] In an embodiment, the central spine runs coronally.
[0034] In an embodiment, the central spine runs sagitally.
[0035] In an embodiment, a plurality of the panels are anchored to the central spine.
[0036] In an embodiment, the central spine has a bias towards extension.
[0037] In an embodiment, the central spine has a bias towards flexion.

100381 In an embodiment, the central spine comprises a biasing member that is coupled to an inside surface of the central spine.
[0039] In an embodiment, the central spine comprises a biasing member that is coupled to an outside surface of the central spine.
[0040] In an embodiment, the biasing member extends through one or more apertures in the central spine, thereby securing the biasing member to the outer surface while allowing the biasing member to slide relative to the central spine during bending.
[0041] In an embodiment, ends of the biasing member extend through apertures in the central spine, such that as the central spine bends the biasing member is free to slide relative to the central spine while remaining substantially abutting the outer surface.
[0042] In an embodiment, the protective layer is coupled to a securing mechanism to secure the impact protection system to the user.
[0043] In an embodiment, the protective layer is made of at least one of: a thermoplastic polymer; ABS (Acrylonitrile Butadiene Styrene); PP (Polypropylene); PC
(Polycarbonate);
Kevlar; and, HDPE (High-density polyethylene).
[0044] In an embodiment, the protective layer comprises at least one of: a honeycomb structure; one or more holes that allow airflow therethrough; surface features that enhance localised flexibility; variable thickness; and, ribbing.
[0045] In an embodiment, the impact protection system comprises a visual indicator indicative of a damage state of the impact protection system.
[0046] In an embodiment, the visual indicator undergoes a colour change following an impact with the impact protection system.
[0047] In an embodiment, the impact protection system comprises an adjustment mechanism to at least partially adjust the size of the impact protection system.

100481 In an embodiment, the adjustment mechanism comprises: one or more tensioning members; an elasticated tensioning system; a ratchet tensioning system; and, an adjustable internal frame.
[0049] In an embodiment, the impact protection system can be folded or squashed for storage.
[0050] In an embodiment, the width of the impact protection system when folded relative to the width in a neutral position is reduced by at least one of: 40%; 50%; 60%;
and, 70%.
[0051] It will be appreciated that the broad forms of the invention and their respective features can be used in conjunction and/or independently, and reference to separate broad forms is not intended to be limiting. Furthermore, it will be appreciated that features of the method can be performed using the system or apparatus and that features of the system or apparatus can be implemented using the method.
Brief Description of the Drawings [0052] Various examples and embodiments of the present invention will now be described with reference to the accompanying drawings, in which: -[0053] Figure 1 is a front left angled view of an impact protection system according to an embodiment of the invention;
[0054] Figure 2 is a front view of the impact protection system from Figure 1;

[0055] Figure 3 is a left side view of the impact protection system from Figure 1;
[0056] Figure 4 is a rear view of the impact protection system from Figure 1;
[0057] Figure 5 is a bottom view of the impact protection system from Figure 1;
[0058] Figure 6 is a top view of the impact protection system from Figure 1;
[0059] Figure 7 is a bottom right angled view of the impact protection system from Figure 1 with a deformable layer removed;

100601 Figure 8 is an upper rear right angled view of the impact protection system from Figure 1;
[0061] Figure 9 is an enlarged view of an edge of a panel from the impact protection system from Figure 1;
[0062] Figure 10 is a side view of another embodiment of the impact protection system in a collapsed position;
[0063] Figure 11 is a rear view of the impact protection system from Figure 10 in a neutral position;
[0064] Figure 12 is a rear view of the impact protection system from Figure 10 in the collapsed position;
[0065] Figure 13 is an upper front right angled view of another embodiment of the impact protection system;
[0066] Figure 14 is a side view of the impact protection system from Figure 13;
[0067] Figure 15 is a bottom view of the impact protection system from Figure 13;
[0068] Figure 16 is an enlarged bottom view of a portion of the impact protection system from Figure 13 with a neck padding partially removed;
[0069] Figure 17 is a top view of the neck padding that optionally forms part of the impact protection system;
[0070] Figure 18 is a side view of the impact protection system from Figure 13 with an alternative form of neck padding;
[0071] Figure 19 is lower front left angled view of another embodiment of the impact protection system; and [0072] Figure 20 is an enlarged portion of Figure 19 as identified by Detail A.

Detailed Description of the Preferred Embodiments [0073] An example of an impact protection system in accordance with an embodiment of the invention will now be described.
[0074] In this example, the impact protection system is suitable for wearing on a head of a user and has a protective layer formed from a plurality of panels. At least one of the panels can translate relative to one or more of the other panels a sufficient amount to facilitate a change in the shape of the protective layer.
[0075] Such a system is advantageous because it can adapt to allow the impact protection system to accommodate a variety of head shapes and sizes. This in turn makes the system more comfortable for the user, as well as potentially making a single design and/or size suitable for a wider range of users.
[0076] Typically, the outer shell of a traditional helmet would be made to be larger than required, with foam padding pieces of various sizes being provided to "pad out" the helmet to fit the particular user. This results in the overall size of the helmet being much larger than the user's head, creating a bulky appearance. In an attempt to address this issue, the helmet may be provided in a large number of sizes, but the user would still often need a slightly larger size to accommodate their particular head shape. As such, by providing a system that can change shape, this bulky appearance can be greatly reduced because the system adapts to the shape of the user's head.
[0077] Additionally, the impact protection system may have a sufficient range of shapes to allow the system to be collapsed, folded, squashed, or otherwise adapted to occupy a smaller or more convenient shape for transport when not in use. For example, the change in shape may allow the impact protection system to be more easily packed into luggage.
Similarly, the ability to change shape may prevent damage to the impact protection system in these or other similar situations.
[0078] A number of further example features will now be described.
[0079] In some examples of the impact protection system, the panels may be flexible. This can allow the system to take an even wider range of shapes and/or may make the system more resilient to damage when not being worn. For example, if the impact protection system was to be squashed when packed in luggage, it may be able to bend to absorb the force, as opposed to a traditional helmet that may crack, for example. In some examples, the width of the impact protection system may be reduced by 40%, 50%, 60%, or even potentially 70% or more, without any permanent damage.
[0080] The impact protection system may be designed so that at least some of the panels that are adjacent partially overlap. By doing so, this can allow the adjacent panels to translate relative to one another without creating a gap between the panels. Depending on the specific design, this may be for all or only a portion of the relative movement. In any event, preventing a gap from forming, or at least limiting the size of the gap, is advantageous because such a gap could potentially allow a sharp object to penetrate the protection system more easily.
[0081] The overlapping of the panels may be achieved by any of a range of means, such as a lap join, a half lap join, or tapered edges of the panels. The half lap join and tapered edges are both advantageous because they allow the overlapping to occur without an increase in the overall thickness of the protective layer. They also limit the possibility of the panels catching as they move toward one another after being separated. The half lap join may also be advantageous in some situations because it creates a stop point to limit the amount that the panels will overlap.
[0082] Where adjacent panels meet, one of the panels may also be provided with a notch or other similar cutout, while the adjoining panel has a tab or other similar protrusion to match the cutout. In this way, the tab fits within the notch to locate the panels in a neutral position.
That is, the panels may be pulled apart from one another, but when moved back together again the tab and the notch guide the panels into their preferred location.
[0083] These features may also be used to constrain the direction of the relative translation of the panels. In particular, the notch and tab may prevent relative movement that is parallel to the adjoining edges while allowing translation that is normal to the edges.
[0084] In some embodiments, the impact protection system may have a deformable layer inside the protective layer so as to face a wearer in use. This deformable layer may be made from or at least include any of a range of materials, such as but not limited to an impact absorbing foam, an elastically deformable layer, a plastically deformable layer, a plastic, a rubber, an auxetic material, a deformable fluid layer, Kevlar, an EPU (Expanded PolyUrethane) foam, an EPS
(Expanded Polystyrene) foam, an EPP (Expanded Polypropylene) foam, and a PPS
(Polyphenylene Sulfide) foam.
[0085] By providing a deformable layer inside the protective layer in this way, a broader range of impact types may be protected against. For example, the protective layer may protect against penetration by a sharp object, while the deformable layer is more effective at absorbing and distributing the energy of a blunt force.
[0086] In these or other embodiments, the deformable layer may have a shear thickening or non-Newtonian component. For example, the deformable layer may include materials such as, but not limited to, a shear thickening foam, a shear thickening moulded foam, a polymer matrix with a shear thickening additive, a foam with non-Newtonian fluid filling, a non-Newtonian material, a polyurethane energy-absorbing material, and a polyurethane material containing Polyborodimethylsiloxane.
[0087] Providing a shear thickening or non-Newtonian component in the deformable layer is particularly advantageous because it may provide an improved comfort level during normal use and/or improving the protection against an impact. The ability of the material to have different properties when a force is applied may allow it to achieve these seemingly competing requirements.
[0088] In one example, the shear thickening or non-Newtonian component has a thickness that is approximately 5mm. In other examples, this component may have a thickness less than 5mm, less than 20mm, greater than 1 Omm, between 5 and 20mm, between 10 and 15mm, less than 30mm, or approximately 30mm.
[0089] The deformable layer and the protective layer may be at least partially coupled using a range of methods, such as but not limited to mechanical bonding, chemical bonding, welding, adhesive, and fasteners. The deformable layer may be removable, such as if the coupling uses a hook and loop fastener or press studs, for example.

100901 In one example, the deformable layer has a thickness that is approximately 15mm;
greater than 20mm, greater than 23mm, less than 26mm, less than 30mm, between 20 and 25mm, between 23 and 26mm, or approximately 30mm. Most typically, the thickness will be approximately 23mm to 26mm, depending on the specific shape chosen. The protective layer may have a thickness of approximately lmm, greater than lmm, greater than 1.5mm, less than 3mm, less than 4mm, between 1 and 4mm, between 1.5 and 3mm, or about 4mm. A
thinner lightweight arrangement is most preferred, with the thickness typically in the range of approximately 1.5mm to 3mm.
[0091] Typically, the deformable layer can be formed as a plurality of sections that are each attached to a single one of the panels. These sections may be completely independent, or may be partially coupled or linked in some way. By providing the deformable layer in this way, it allows the panels to translate relative to one another without any impediment from the deformable layer. The sections of the deformable layer may also have chamfered edges to accommodate the translation of the panels without causing interference.
[0092] In some embodiments, the deformable layer may have a cover extending over an inner surface, so that it abuts the head of the user during use. This cover can be made of any suitable material, such as but not limited to a woven fabric, a non-woven fabric, an elasticated fabric, and an open cell foam. For example, in one preferred form, the cover may be a knitted wool or synthetic material, most preferably merino wool.
[0093] In some embodiments, the protective layer may have a cover extending over an outer surface. This cover can be made of any suitable material, such as but not limited to a woven fabric, a non-woven fabric, an elasticated fabric, and an open cell foam. For example, in one preferred form, the cover may be a knitted wool or synthetic material, most preferably a polyester/acrylic fabric, giving the appearance of a "beanie" or "knit cap".
[0094] In this way, the impact protection system can potentially have an appearance that may be considered more attractive than a traditional helmet while still providing similar protective benefits. The ability of the impact protection system to change shape can also assist with imitating a beanie, because the system will better conform to the shape of the user's head in much the same way that a beanie does.

[0095] In some embodiments, a flexible member may extend downwardly from a lower edge of a rear portion of the deformable layer. The flexible member may be configured to abut and substantially conform to a shape of a user's head and/or neck during use. For example, it may conform to the user's head shape, particularly in the region of the occipital bone, which could improve the fit and feel of the impact protection system.
[0096] In some optional embodiments of the impact protection system, the panels are connected to one another to limit a width of a gap that can form when adjacent panels translate away from one another. For example, adjacent panels may be connected by an elastic tether, an inelastic strap, a flexible band, a rigid brace, or some other form of coupler that allows the panels to move apart only to a point where they are then constrained from moving any further apart. This connection means may involve a hard limit where the panels are free to move before being stopped, or be a more gradual limit where a resisting force gradually increases with the distance.
[0097] In one example, the protective layer may include at least one backing member that spans the gap caused when the panels translate away from one another. Such a backing member addresses the issue raised previously, where a gap between the panels may also sacrifice safety because sharp objects can penetrate the gap. Instead, the backing member can allow the panels to move apart enough that a gap forms, while maintaining a complete cover for penetration resistance.
[0098] In one specific example, the backing member may have a groove and the panels on either side of the backing member have at least one pin that extends into the groove. The pins and groove cooperate to allow but also limit relative translation between the panels that are connected by the backing member. The backing member may extend along a join between panels with a series of grooves and respective pins to couple with each groove.
[0099] This design of backing member is advantageous because it allows free movement between the panels until the hard limit is reached when the pins reach the ends of the groove.
If it is desirable to have resistance to the panels moving apart, however, an elastic tether or other similar device could be used in conjunction with the backing member.

[0100] In some embodiment, the relative translation between the panels can occur in three dimensions. That is, the panels can preferably translate within a plane of the panels both normal to the edge and along the edge, as well as in a direction normal to the plane of the panels. In other embodiments, however, the relative translation may occur in only two or even one dimension. For example, the panels may be restricted from relative translation outside the plane of the panels. In other examples, this direction may be possible but they may not be able to translate in a direction parallel to the edge. In yet other examples, they may be restricted to only translating in the direction within the plane and normal to the edge.
[0101] In some example embodiments of the impact protection system, one of the panels may be a central spine that is flexible. In various alternative embodiments, the central spine may run coronally (from ear to ear), while in other alternative embodiments the central spine may run sagittally (from front to back).
[0102] In one such embodiment, a plurality of the panels may be anchored to the central spine. For example, the central spine may extend from the front to the back of the impact protection system, with each of the remaining panels extending from the central spine and being anchored thereto. This anchoring may use any suitable fastening means, such as but not limited to a clip, a fastener, or an adhesive.
[0103] In some optional embodiments, the central spine may play a role in forming the shape of the impact protection system and/or assisting to maintain a comfortable fit of the system. In some cases, this could be achieved by the central spine having a bias towards extension, while in others it could be achieved by the central spine having a bias towards flexion.
[0104] For example, if the central spine has a bias towards extension, this means that the central spine will have a tendency towards lying flat, rather than being curved. If the central spine runs sagittally, then this will cause the front and the back of the impact protection system to move apart, resulting in the sides moving inwardly. This can cause the impact protection system to have a collapsed or "squashed" shape when not being worn, and can cause the sides to "hug" the head of the user when being worn. This in turn may create an improved and/or more secure fit, or at least provide such a perception to the user.

[0105] In some of these embodiment, the bias of the central spine may be achieved using a biasing member that is coupled to an outside surface or an inside surface of the central spine.
This biasing member may be a resiliently deformable member made from any suitable material, such as but not limited to plastic, metal, carbon fibre, or another composite material.
[0106] In one example, the biasing member may extend through one or more apertures in the central spine, thereby securing the biasing member to the outer surface while allowing the biasing member to slide relative to the central spine during bending. That is, the aperture provides a mechanical means of coupling the biasing member to the central spine while still allowing enough relative movement as will be necessary through the range of motion of the central spine.
[0107] Similarly, the ends of the biasing member may extend through apertures in the central spine, so that as the central spine bends the biasing member is free to slide relative to the central spine while remaining substantially abutting the outer surface.
Otherwise stated, as the central spine bends the biasing member will also bend with it, but because it is located against an outer surface the overall length required will change due to the changing radius.
Therefore, as the central spine extends the biasing member can move further into the apertures and as the central spine flexes the biasing member cam move back out of the apertures. Thus, the biasing member can accommodate the changing radius of the central spine without causing any restriction.
[0108] In some embodiments, the protective layer may be coupled to a securing mechanism to secure the impact protection system to the user. For example, a strap with a buckle may be connected to two or more locations on the protective layer, so that the strap can pass under the chin of the user and secure the system in place. It will be appreciated, however, that various alternative securing mechanisms could also be used, as will be known to those skilled in the art.
[0109] The protective layer can be made of any suitable material or combination of materials as will be appropriate for the particular design and intended use.
These materials could include, but are not limited to, at least one of a thermoplastic polymer, ABS
(Acrylonitrile Butadiene Styrene), PP (Polypropylene), PC (Polycarbonate), Kevlar, and HDPE (High-density polyethylene). Preferably, the material will be resistant to penetration by a sharp object, while still having at least some degree of flexibility. The material will also preferably be lightweight and able to perform adequately while being as thin as possible.
[0110] The protective layer may also optionally include one of a variety of other features to aid in strength, comfort or performance, such as a honeycomb structure, one or more holes that allow airflow therethrough, surface features that enhance localised flexibility, variable thickness, ribbing, and/or any other features as may be known to those skilled in the art.
[0111] The impact protection system may also have a visual indicator indicative of a damage state of the impact protection system. For example, the visual indicator could undergo a colour change following an impact with the impact protection system. Such an indicator would be advantageous for simple identification of situations when the impact protection system requires repair or replacement, which otherwise may not be obvious or even possible to tell without the use of sophisticated testing equipment.
[0112] The impact protection system may also have an adjustment mechanism to at least partially adjust the size of the impact protection system. For example, the adjustment mechanism could have one or more tensioning members, an elasticated tensioning system, a ratchet tensioning system, an adjustable internal frame, and/or any other suitable mechanism as may be known to those skilled in the art.
[0113] An example of a preferred embodiment of the invention will now be described with reference to Figures 1 to 9.
[0114] Referring to Figure 1, an impact protection system in the form of a helmet 100 is shown. The helmet 100 has a protective layer 101 towards the outside and a deformable layer 102 towards the inside facing a user's head during use.
[0115] The protective layer 101 is made up of panels 104 that are connected to a central spine 105. The central spine 105 has a biasing member 106 extending along an outer surface thereof

- 16 -[0116] Referring to Figure 3, the panels 104 can be seen in more detail, together with anchor points 108 for securing a strap or other similar device for securing the helmet 100 to the user. There are three panels 104 along each side of the helmet 100, each connected to the central spine 106 and one or more adjacent panels 104.
[0117] The joins 110 between adjacent panels 104 are also shown in Figure 3. It can be seen that some panels 104 include a tab 111 that couples with a notch in the adjacent panel.
The notch and tab 111 ensure that the panels are correctly located when returned to a neutral position after being separated.
[0118] Figure 9 shows the edge of a panel 104 in more detail, including the tab 111. It also shows that the panels have a cutout to create a half-thickness section 112 that couples with a reverse half-thickness section on the adjacent panel 104. Together, these thin sections create a half lap join between the adjacent panels 104. That is, the thin sections overlap to create an overlapping section that has a thickness no greater than the typical thickness of either panel.
[0119] Referring now to Figure 7, the inside of the joins 110 between panels 104 is shown with the deformable layer 102 removed for clarity. A backing member 115 spans the join 110 and is attached to each panel 104 using pins 116 extending from the panels 104 through grooves 117 in the backing member 115. A clip 118 at an upper end of the backing member 115 anchors the backing member 115 to the central spine 105. The panels 104 are also anchored to the central spine 105 by clips 120.
[0120] It will be clear that the joins 110 between adjacent panels 104 allow a degree of separation. That is, the panels 104 can be pulled apart from one another, with the pins 116 sliding along the grooves 117 in the backing member 115 to allow this to occur. For an initial part of this movement, the half-thickness sections 112 will still be partially overlapping to prevent any gap forming. Towards the end of the movement, however, a gap may form between the panels 104. Despite this, the backing member still provides a level of protection from penetration of an external object through the gap.
[0121] The join between the panels 104 and the central spine 105 cannot be pulled apart in this manner, however a degree of pivot and/or bending can occur to allow the relative

- 17 -movement between panels 104. It will be appreciated, however, that a similar join and backing member could be provided at this location in an alternative embodiment.
[0122] The end result is a helmet 100 that facilitates a change of shape.
For example, the sides of the helmet 100 can be pushed inwardly, allowing the helmet 100 to be "squashed".
This is accommodated by necessary parts of the joins 110 between the panels 104 pulling apart from one another. That is, the join 110 does not necessarily need to separate evenly along the length, but rather may separate more at one location than another, depending on the desired change in shape of the helmet 100. It is also possible for the panels 104 to translate relative to one another in three dimensions when necessary, such as by part of a panel 104 being raised above or outside the plane of the panels 104, while another part of the join 110 is pulled apart within the plane.
[0123] The change in shape of the helmet 100 is also assisted by the panels 104 having some flexibility. In the embodiment being described, the panels 104 would typically be made from a high density polyethylene (HDPE) that is tough and resistant to penetration while also being somewhat flexible, but it will be appreciated that many other materials could alternatively be used.
[0124] Referring to Figure 8, the central spine 105 can be seen in some detail. The biasing member 106 abuts an outer surface of the central spine 105 and is held against the central spine 105 by a bridge 122 under which the biasing member 106 passes. A raised section 123 towards each end also creates an aperture into which the biasing member 106 enters, thereby also holding the ends of the biasing member 106 against the central spine 105.
[0125] The biasing member 106 has a natural shape that is closer to flat than the curved shape as shown in the Figures. Accordingly, the biasing member 106 provides a force in an outward direction at the ends thereof That is, the biasing member 106 has a tendency towards extension. As the helmet 100 is able to change shape as described previously, the biasing member 106 has the effect of causing the front and rear parts of the helmet 100 to move outwardly and the sides to move inwardly.
[0126] As the shape of the helmet 100 changes, the biasing member 106 is able to slide relative to the central spine 105 to accommodate this movement. The biasing member 106 may

- 18 -be fixed at the bridge 122, but can slide further in or out of the raised sections 123 at each end as necessary.
[0127] Referring to Figure 5, the deformable layer is shown in more detail.
Here it can be seen that the deformable layer is made up of individual foam pads 102, each attached to a different one of the panels 104. They are held in place using a hook and loop fastener, but it will be appreciated that other securing mechanisms could alternatively be used. The edges of the foam pads 102 are chamfered to create gaps between the pads 102, ensuring that there is no interference as the panels 104 translate relative to one another, such as when the helmet 100 is folded, for example.
[0128] While not shown in the Figures, the helmet 100 would preferably be provided with an outer cover, which may be fabric or another soft material. A knitted wool cover, for example, would typically be used in embodiments of the helmet 100 intended for snow sports. This would give the appearance of a beanie, while still having the necessary protective properties.
The ability of the helmet 100 to change shape would also further assist in achieving the "beanie" appearance.
[0129] An alternative example of an embodiment of the invention is shown in Figures 10 to 12. Referring to Figure 10, the relative movement of adjacent panels 204 of the helmet 200 when in the collapsed position can be more clearly seen. At a lower end of the join 210, a significant gap is seen between the panels 204. Toward an upper end of the join 204, however, there is no gap of even additional overlap in comparison to the neutral position.
[0130] Figures 11 and 12 illustrate the ability of the helmet 200 to be collapsed or squashed. Figure 11 shows the helmet 200 in a neutral position as taken when there are no external forces being applied, while Figure 12 shows that the helmet 200 is collapsed with relatively little inward pressure when the helmet 200 is not being worn.
[0131] Yet another embodiment of the invention is shown in Figures 13 to 17. Referring in particular to Figures 13 to 15, an optional neck padding 330 is fitted to the helmet 300. In use, the neck padding 330 extends downwardly from the rear of the helmet 300 and contacts the back of the user's neck, providing additional warmth and/or comfort, and potentially providing a fit with a more secure feel.

- 19 -[0132] The neck padding 330 is a piece of foam that is shaped to fit around the occipital bone at the rear of the user's head. It extends beyond a typical helmet line, and can provide extra fastening around the occipital protuberance. The neck padding 330 is also shaped in a way that cups around the top of the user's ears to complete the feel and to help locate the piece.
The neck padding 330 is made of a mid-firmness foam that has enough flexibility to be able to be pulled in around the head, but also is firm enough to make it feel like a solid piece around the back of the head. It will be appreciated that alternative materials and/or firmness of the foam could be used, however, or options potentially even provided to the user.
[0133] This addition to the helmet 300 also allows the helmet 300 to more closely imitate the look and feel of a beanie, as this more closely represents the position that a beanie would sit on the user's neck.
[0134] An outer sock 332 of the neck padding 330 extends around the perimeter of the protective layer 301 of the helmet 300, with a web 333 extending over the top of the panels 304. The sock 332 and web 333 are made from neoprene, but it will be appreciated that alternative materials could be used. Importantly, the material should be flexible and have sufficient elasticity, as it is responsible for the articulating and conforming to the back of the head.
[0135] As shown in Figure 15, the neck padding 330 itself extends downwardly from the deformable layer 302, effectively forming an extension of the deformable layer 302. Figure 16 shows that the deformable layer 302 has hook and loop fasteners 335 attached to assist with securing the neck padding 330 in position.
[0136] In Figure 17, the neck padding 330 itself is shown separated from the deformable layer 302 and the outer sock 332. Cutouts 336 are visible, which are provided to conform to the user's ears. Meanwhile, Figure 18 shows a different design of neck padding 340, where the outer sock 332 and web 333 are not required.
[0137] Referring to Figure 16, the deformable layer is shown in more detail. Here it can be seen that the deformable layer is made up of individual pads 302, each attached to a different one of the panels 304. In this embodiment, the pads 302 are made from a non-Newtonian foam with Polyurethane inserts 350.

- 20 -[0138] Figures 19 and 20 shown another embodiment of a helmet 400. In this embodiment, holes 445 are provided in the deformable layer 402 to house inserts in the deformable layer 402, which is made from a shear thickening or non-Newtonian material.
[0139] In the foregoing description of preferred embodiments, specific terminology has been resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as "front" and "rear", "inner" and "outer", "above" and "below" and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms [0140] Throughout this specification and claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or group of integers or steps but not the exclusion of any other integer or group of integers. As used herein and unless otherwise stated, the term "approximately" means 20%.
[0141] It must be noted that, as used in the specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a support" includes a plurality of supports. In this specification and in the claims that follow, reference will be made to a number of terms that shall be defined to have the following meanings unless a contrary intention is apparent.
[0142] Persons skilled in the art will appreciate that numerous variations and modifications will become apparent. All such variations and modifications which become apparent to persons skilled in the art, should be considered to fall within the spirit and scope that the invention broadly appearing before described.

Claims (43)

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1) An impact protection system for wearing on a head of a user, the impact protection system comprising a protective layer formed from a plurality of panels, wherein at least one of the panels can translate relative to one or more of the other panels a sufficient amount to facilitate a change in the shape of the protective layer.

2) The impact protection system according to claim 1, wherein the panels are flexible.

3) The impact protection system according to any one of the preceding claims, wherein at least some of the panels that are adjacent partially overlap.

4) The impact protection system according to claim 3, wherein the overlapping of the panels comprises a half lap join.

5) The impact protection system according to any one of the preceding claims, wherein one of the panels comprises a notch and another one of the panels comprises a tab, such that the tab fits within the notch to locate the panels in a neutral position.

6) The impact protection system according to any one of the preceding claims, further comprising a deformable layer inside the protective layer so as to face a wearer in use.

7) The impact protection system according to claim 6, wherein the deformable layer comprises a shear thickening or non-Newtonian component.

8) The impact protection system according to claim 7, wherein the deformable layer comprises at least one of:
a) a shear thickening foam;
b) a shear thickening moulded foam;
c) a polymer matrix comprising a shear thickening additive;
d) a foam with non-Newtonian fluid filling;
e) a non-Newtonian material;
f) a polyurethane energy-absorbing material; and, g) a polyurethane material containing Polyborodimethylsiloxane.

9) The impact protection system according to any one of claims 7 or 8, wherein the shear thickening or non-Newtonian component has a thickness that is at least one of:
a) ¨5mm;
b) <5mm;
c) <20mm;
d) >10mm;
e) 5-20mm;
f) 10-15mm;
g) <30mm; and, h) ¨30mm;

10)The impact protection system according to any one of claims 6 to 9, wherein the defomiable layer is made of at least one of:
a) an auxetic material;
b) a deformable fluid layer;
c) an impact absorbing foam;
d) an elastically deformable layer;
e) a plastically deformable layer;
f) a plastic;
g) a rubber;
h) Kevlar;
i) an EPU (Expanded PolyUrethane) foam;
j) an EPS (Expanded Polystyrene) foam;
k) an EPP (Expanded Polypropylene) foam; and, 1) a PPS (Polyphenylene Sulfide) foam.

11)The impact protection system according to any one of claims 6 to 10, wherein the deformable layer and the protective layer are at least partially coupled using at least one of:
a) mechanical bonding;
b) chemical bonding;
c) welding;

d) adhesive; and, e) fasteners.

12)The impact protection system according to any one of claims 6 to 11, wherein the deformable layer is removable.

13)The impact protection system according to any one of claims 6 to 12, wherein:
a) the deformable layer has a thickness that is at least one of:
i) ¨15mm;
ii) >20mm;
iii) >23mm;
iv) <26mm;
v) <30mm;
vi) 20-25mm;
vii) 23-26mm; and, viii) ¨30mm; and, b) the protective layer has a thickness that is at least one of:
i) ¨1mm;
ii) >lmm;
iii) >1.5mm;
iv) <3mm;
v) <4mm;
vi) 1-4mm;
vii) 1.5-3mm; and, viii) ¨4mm.

14)The impact protection system according to any one of claims 6 to 13, wherein the deformable layer comprises a plurality of sections that are each attached to a single one of the panels.

15)The impact protection system according to claim 14, wherein the plurality of sections of the deformable layer comprise chamfered edges to accommodate the translation of the panels.

CA 03224657 2023-12-18 - 24 -16)The impact protection system according to any one of claims 6 to 15, wherein a flexible member extends downwardly from a lower edge of a rear portion of the defomiable layer.

17)The impact protection system according to claim 16, wherein the flexible member is configured to abut and substantially confomi to a shape of a user's head and/or neck during use.

18)The impact protection system according to any one of claims 6 to 17, wherein the defomiable layer has a cover extending over an inner surface so as to be located between the deformable layer and the head of the user during use, the cover being made of at least one of:
a) a woven fabric;
b) a non-woven fabric;
c) an elasticated fabric; and, d) an open cell foam.

19)The impact protection system according to any one of the preceding claims, wherein the protective layer has a cover extending over an outer surface, the cover being made of at least one of:
a) a woven fabric;
b) a non-woven fabric;
c) an elasticated fabric; and, d) an open cell foam.

20)The impact protection system according to any one of the preceding claims, wherein the panels are connected to one another to limit a width of a gap that can form when adjacent panels translate away from one another.

21)The impact protection system according to claim 20, wherein the panels are connected by at least one of:
a) an elastic tether;
b) an inelastic strap;

c) a flexible band; and, d) a rigid brace.

22)The impact protection system according to any one of claims 20 or 21, wherein the protective layer comprises at least one backing member that spans the gap caused when the panels translate away from one another.

23)The impact protection system according to claim 22, wherein the backing member comprises at least one groove and the panels on either side of the backing member comprise at least one pin that extends into the groove, the pins and groove thereby cooperating to allow but also limit relative translation between the panels that are connected by the backing member.

24) The impact protection system according to any one of the preceding claims, wherein the relative translation between the panels can occur in three dimensions.

25) The impact protection system according to any one of the preceding claims, wherein one of the panels is a central spine that is flexible.

26) The impact protection system according to claim 25, wherein the central spine runs coronally.

27) The impact protection system according to claim 25, wherein the central spine runs sagitally.

28) The impact protection system according to any one of claims 25 to 27, wherein a plurality of the panels are anchored to the central spine.

29) The impact protection system according to any one of claims 25 to 28, wherein the central spine has a bias towards extension.

30) The impact protection system according to any one of claims 25 to 28, wherein the central spine has a bias towards flexion.

31) The impact protection system according to any one of claims 25 to 28, wherein the central spine comprises a biasing member that is coupled to an inside surface of the central spine.

32) The impact protection system according to any one of claims 25 to 28, wherein the central spine comprises a biasing member that is coupled to an outside surface of the central spine.

33) The impact protection system according to claim 32, wherein the biasing member extends through one or more apertures in the central spine, thereby securing the biasing member to the outer surface while allowing the biasing member to slide relative to the central spine during bending.

34) The impact protection system according to any one of claims 32 or 33, wherein ends of the biasing member extend through apertures in the central spine, such that as the central spine bends the biasing member is free to slide relative to the central spine while remaining substantially abutting the outer surface.

35)The impact protection system according to any one of the preceding claims, wherein the protective layer is coupled to a securing mechanism to secure the impact protection system to the user.

36)The impact protection system according to any one of the preceding claims, wherein the protective layer is made of at least one of:
a) a themioplastic polymer;
b) ABS (Acrylonitrile Butadiene Styrene);
c) PP (Polypropylene);
d) PC (Polycarbonate);
e) Kevlar; and, f) HDPE (High-density polyethylene).

37)The impact protection system according to any one of the preceding claims, wherein the protective layer comprises at least one of:
a) a honeycomb structure;
b) one or more holes that allow airflow therethrough;
c) surface features that enhance localised flexibility;
d) variable thickness; and, e) ribbing.

38) The impact protection system according to any one of the preceding claims, wherein the impact protection system comprises a visual indicator indicative of a damage state of the impact protection system.

39) The impact protection system according to claim 38, wherein the visual indicator undergoes a colour change following an impact with the impact protection system.

40) The impact protection system according to any one of the preceding claims, wherein the impact protection system comprises an adjustment mechanism to at least partially adjust the size of the impact protection system.

41)The impact protection system according to claim 40, wherein the adjustment mechanism comprises:
a) one or more tensioning members;
b) an elasticated tensioning system;
c) a ratchet tensioning system; and, d) an adjustable internal frame.

42) The impact protection system according to any one of the preceding claims, wherein the impact protection system can be folded or squashed for storage.

43)The impact protection system according to any one of the preceding claims, wherein the width of the impact protection system when folded relative to the width in a neutral position is reduced by at least one of:
a) 40%;
b) 50%;
c) 60%; and, d) 70%.