CN111264967A

CN111264967A - Helmet padding system

Info

Publication number: CN111264967A
Application number: CN201911235246.6A
Authority: CN
Inventors: 罗伯特·A·维托
Original assignee: Matscitechno Licensing Co
Current assignee: Matscitechno Licensing Co
Priority date: 2018-12-05
Filing date: 2019-12-05
Publication date: 2020-06-12
Also published as: EP3662774A1

Abstract

A helmet padding system is disclosed. A helmet padding system includes a rigid shell configured to cover the top of a user's head and to be worn under a piece of headgear. The rigid housing includes a first pair of slots configured to extend in a direction from a rear of the user's head toward a front of the user's head when the rigid housing is worn on the user's head. The first pair of slots defines a central portion and opposing side portions of the rigid housing. The central portion includes at least one tab extending from the central portion across one of the first pair of slots and covering a first area of one of the opposing side portions of the rigid shell. The spacer pads are positioned within the rigid housing.

Description

Helmet padding system

Cross Reference to Related Applications

This application is a continuation-in-part application of U.S. patent application No.15/923,117 filed on day 16/3/2018, U.S. patent application No.15/923,117 is a continuation-in-part application of U.S. patent application No.15/898,814 filed on day 19/2/2018, U.S. patent application No.15/898,814 is a continuation-in-part application of U.S. patent application No.15/644,145 filed on day 7/2017, U.S. patent application No.15/644,145 is a continuation-in-part application of U.S. patent application No.15/488,650 filed on day 17/4/2017, U.S. patent application No.15/488,650 is a continuation-in-part application of U.S. patent application No.14/729,266 filed on day 3/6/2015, U.S. patent application No.14/729,266 is a continuation-in-part application of U.S. patent application No.14/493,869 filed on day 23, U.S. patent application No.14/493,869 is a continuation-in-part application of U.S. patent application No.14/275,046 filed 5, 12/2014. U.S. patent application No.14/493,869 is also a non-provisional application for U.S. patent application No.61/942,743 filed on 21/2/2014. The entire contents of each of the above applications are incorporated herein by reference.

Technical Field

The present invention relates generally to the field of protective headgear, and more particularly to an impact resistant liner for protective headgear.

Background

Conventionally, participants in "touch" sports (e.g., wrestling, soccer, football) wear protective headgear to cushion the impact forces that are often received during these activities. In recent years, the negative health effects of the impact on the head experienced during such contact movements have been a concern. These negative health effects can be reduced or mitigated by effectively mitigating the impact forces experienced by the participants. Accordingly, there is a need for improved structures, such as impact resistant headgear, to mitigate the impact forces experienced by participants.

Disclosure of Invention

Aspects of the present invention relate to helmet padding systems.

According to one aspect of the invention, a helmet liner system includes a rigid shell and a spacer liner. The rigid shell is configured to cover the top of a user's head and to be worn under a piece of headgear. The rigid housing includes a first pair of slots configured to extend in a direction from a rear of the user's head toward a front of the user's head when the rigid housing is worn on the user's head. The first pair of slots defines a central portion and opposing side portions of the rigid housing. The central portion includes at least one tab extending from the central portion across one of the first pair of slots and covering a first area of one of the opposing side portions of the rigid shell. The spacer pads are positioned within the rigid housing.

Drawings

The invention is best understood from the following detailed description when read with the accompanying drawing figures, in which like elements are given like reference numerals. When there are a plurality of similar elements, a single reference numeral may designate the plurality of similar elements by a lower case letter designation referring to the specific element. Lower case letter designations may be omitted when referring to common elements or to one or more elements that are not specific. In accordance with common practice, the various features of the drawings are not drawn to scale unless otherwise indicated. On the contrary, the dimensions of the various features may be exaggerated or minimized for clarity. Included in the drawings are the following figures:

fig. 1 is an image illustrating an exemplary helmet padding system according to aspects of the present disclosure;

fig. 2 is an image showing an exemplary helmet shell of the helmet padding system of fig. 1;

fig. 3 is an image showing an exemplary absorbent pad of the helmet liner system of fig. 1;

fig. 4 is an image showing an exemplary spacer pad of the helmet padding system of fig. 1;

FIG. 5 is an image of the exemplary spacer of FIG. 4 in a helmet shell;

fig. 6 is an image showing another exemplary spacer pad of the helmet padding system of fig. 1;

FIG. 7 is an image of the example spacer of FIG. 6 in a helmet shell;

fig. 8 is an image showing yet another exemplary spacer pad of the helmet padding system of fig. 1;

fig. 9A-9D are images illustrating exemplary impact resistant pads according to aspects of the present invention;

10A-10C are images illustrating an exemplary protective headgear system according to aspects of the present invention;

FIG. 11 is an image illustrating another exemplary protective headgear system according to an aspect of the present invention;

fig. 12 is a cross-sectional view illustrating another exemplary helmet padding system according to an aspect of the present invention;

fig. 13 is an image showing another exemplary spacer pad of the helmet padding system of fig. 1;

fig. 14A-14D are images illustrating another exemplary helmet padding system according to aspects of the present disclosure;

fig. 15A-15C are images illustrating an alternative embodiment of the exemplary helmet padding system of fig. 14A-14D;

fig. 16-18 are images illustrating an embodiment of another exemplary helmet padding system in accordance with aspects of the present invention;

fig. 19A and 19B are images illustrating another exemplary helmet padding system according to aspects of the present disclosure;

fig. 19C and 19D are images illustrating cross-sectional views of the exemplary helmet padding system of fig. 19A and 19B;

fig. 20A and 20B are images showing an alternative embodiment of the helmet padding system of fig. 19A and 19B;

FIG. 21 is another image showing the embodiment of FIGS. 20A and 20B in a conventional cap;

fig. 22 and 23 are images illustrating another exemplary helmet padding system according to aspects of the present disclosure;

fig. 24A-24C are images illustrating another exemplary helmet padding system according to aspects of the present disclosure;

fig. 25 is an image showing an exploded embodiment of the helmet padding system of fig. 24A-24C;

fig. 26 is an image showing an alternative embodiment of a cutout of the helmet padding system of fig. 24A-24C;

fig. 27 is an image showing the interior of the helmet padding system of fig. 24A to 24C;

fig. 28A and 28B are images illustrating an alternative embodiment of the helmet padding system of fig. 24A-24C;

fig. 29 is an image showing the helmet padding system of fig. 24A to 24C worn under a baseball cap;

fig. 30A and 30B are images illustrating an alternative embodiment of the helmet padding system of fig. 20A and 20B;

fig. 31A-31C are images showing the helmet padding system of fig. 30A and 30B with a removable plate;

fig. 32A and 32B are images illustrating an alternative embodiment of the helmet padding system of fig. 24A-24C;

fig. 33A and 33B are images illustrating another exemplary helmet padding system in accordance with aspects of the present invention;

fig. 34 is an image showing a top view of the helmet padding system of fig. 33A and 33B;

fig. 35 is an image showing the interior of the helmet padding system of fig. 33A and 33B;

fig. 36A and 36B are images illustrating another exemplary helmet padding system in accordance with aspects of the present invention;

fig. 37 is an image showing the interior of the helmet padding system of fig. 36A and 36B;

fig. 38 is an image showing the helmet padding system of fig. 36A and 36B positioned within a cap;

fig. 39A-39C are images illustrating another exemplary helmet padding system in accordance with aspects of the present invention;

fig. 40A and 40B are images illustrating an alternative embodiment of the helmet padding system of fig. 39A-39C;

41A-41C are images illustrating another exemplary helmet padding system according to aspects of the present disclosure;

fig. 42 is an image showing the helmet padding system of fig. 41A-41C positioned within a cap;

fig. 43A-43C are images illustrating another exemplary helmet padding system in accordance with aspects of the present invention;

fig. 44 is an image showing the helmet padding system of fig. 43A-43C positioned within a cap;

45A-45C are images illustrating another exemplary helmet padding system according to aspects of the present disclosure;

fig. 46 is an image showing the helmet padding system of fig. 45A-45C positioned within a cap;

fig. 47A-47D are images illustrating another exemplary helmet padding system according to aspects of the present disclosure; and

fig. 48A and 48B are images illustrating another exemplary helmet padding system according to aspects of the present disclosure.

Detailed Description

Embodiments of the invention described herein relate to helmet liners and protective headgear systems that incorporate impact resistant liners beneath a user's helmet to cushion the user's head from impact with the helmet. As used herein, the term "helmet" is not meant to be limiting, but is intended to include any headgear worn for protection during activities where impact to the head may occur. Additionally, as used herein, the term "impact-resistant" is intended to include any object that partially or completely mitigates, reduces, dissipates, deflects, or absorbs the mechanical forces of an impact.

The example systems and devices disclosed herein are configured to mitigate impact forces on a user's head. This makes these exemplary systems and devices particularly well suited for use by participants in athletic activities, particularly for participants in traditional "touch" sports such as wrestling, american football, or rugby, which typically experience high impact forces. Although exemplary embodiments of the present invention are described herein with respect to athletic activities, it should be understood that the present invention is not limited thereto. Suitable applications for the system and apparatus of the present invention include, for example, military helmets or construction helmets. Other suitable applications will be readily apparent to those of ordinary skill in the art in view of the description herein.

Referring now to the drawings, fig. 1 illustrates an exemplary helmet padding system 100 in accordance with aspects of the present invention. Helmet liner system 100 may be worn by a user during athletic activities. As a general overview, the system 100 includes a helmet shell 110, a spacing pad 130, and a plurality of absorbent pads 150. Additional details of the system 100 are described herein.

The helmet shell 110 is configured to be positioned on the head of a user. As shown in fig. 1 and 2, the helmet shell 110 completely surrounds the upper portion of the user's head. This may be desirable to ensure that any impact to the user's head is absorbed by the helmet padding system 100. The helmet shell 110 can include one or more straps 112 for securing the helmet shell 110 to the head of a user. The dimensions of the helmet shell 110 are selected such that the helmet shell 110 can accommodate the remaining components of the system 100 while still being securely positioned on the user's head. Where helmet shell 110 is a conventional helmet shell, it will be understood that helmet shell 110 may include its own integrally connected foam pad in addition to the pads described with respect to system 100. It will be understood that the padding for the system 100 may be padding provided in addition to padding provided in a conventional helmet shell 110. Suitable helmet shells 110 for use with the present invention will be known to those of ordinary skill in the art in view of the description herein.

The spacer 130 is positioned inside the helmet shell 110. As shown in fig. 4-8, the spacer pad 130 includes a central portion 132 and a plurality of extensions 134 projecting outwardly from the central portion. The spacer 130 may or may not be coupled to the interior of the helmet shell 110. When the spacer 130 is coupled to the helmet shell 110, the central portion 132 is coupled to a central region of the interior of the helmet shell 110 such that the extension portion 134 protrudes toward a circumferential edge of the helmet shell 110.

The spacer 130 is formed of an impact resistant material. For example, the spacer pads 130 may include a layer of elastomeric material. The elastic material may provide impact resistance by absorbing and dissipating impact forces laterally along the surface of the elastic material. In one exemplary embodiment, the spacer 130 is constructed of only a single layer of resilient material. In another exemplary embodiment, the spacer pad 130 includes two or more layers of elastomeric material. The spacer mat 130 may comprise layers of elastomeric material directly adjacent to each other or, in a more preferred embodiment, may comprise layers of high tensile strength fibrous material between the layers of elastomeric material.

Suitable materials for forming the elastic layer include, but are not limited to, urethane rubber, silicone rubber, nitrile rubber, butyl rubber, acrylic rubber, natural rubber, styrene-butadiene rubber, and the like. In general, any suitable resilient material may be used to form the resilient layer described above without departing from the scope of the present invention. Suitable materials for forming the layer of high tensile strength fibrous material include, but are not limited to, aramid fibers, glass fibers, or other high tensile strength fibers. The fibers may be woven to form a cloth layer disposed between and generally separating the opposing elastic layers. The layer of high tensile strength fibrous material may desirably block and redirect impact energy passing through one of the elastic layers. Further description of the materials used to form the spacer pads 130 may be found in co-pending U.S. patent application No.13/331,004, which is incorporated herein by reference in its entirety.

As shown in fig. 4, the spacer 130 may include a series of raised portions 131 formed on a surface thereof. The convex portion 131 may have a rectangular shape as shown in fig. 4. However, one of ordinary skill in the art will appreciate that other shapes may be selected. For example, the convex portion 131 may have a square shape or a diamond shape. Raised portions 130 desirably enable air to circulate across spacer pads 130 and concentrate the load from the impact on spacer pads 130. A series of raised portions 131 having a diamond shape may be particularly desirable because these raised portions 131 may provide greater flexibility to the spacer pad 130.

As described above, the spacer pad 130 may or may not be coupled to the interior of the helmet shell 110. When the spacer 130 is coupled to the inside of the helmet shell 110, such coupling may be accomplished, for example, using an adhesive. It may be desirable for the surface of the spacer 130, including the entire length of the extension 134, to be adhered to the interior of the helmet shell 110. The length of the extension 134 may be limited to prevent the extension 134 from being separated from the helmet shell 110 during an impact that deforms the helmet shell 110.

The absorbent pad 150 may be coupled to the spacer pad 130. As shown in fig. 3, the plurality of absorbent pads 150 includes a first large absorbent pad 152 and a plurality of remaining absorbent pads 154. As shown in fig. 1, the absorbent pad 152 is configured to be coupled to a central portion of the spacer pad 130, and the absorbent pad 154 is configured to be coupled to an end portion of an extended portion of the spacer pad 130.

The absorbent pad 150 is desirably shaped such that the absorbent pad 150 does not directly contact the helmet shell 110 when the spacer pad 130 is coupled to the helmet shell 110. The absorbent pad 150 may be isolated from the helmet shell 110 by the end of the spacer pad 130, and/or may be formed in a preferred curve to form a gap between the outer surface of the pad 150 and the interior of the helmet shell 110. Suitable materials for forming the absorbent pad 150 include, for example, conventional closed or open cell foams, elastic and/or polymeric materials. Other materials will be known to those of ordinary skill in the art in view of the description herein.

Fig. 4-8 and 13 show different embodiments of

spacer pads

130a, 130b, 130c, 130d for use in the present invention. Each

spacer pad

130a, 130b, 130c, 130d includes a respective

central portion

132a, 132b, 132c, 132d and a respective plurality of

extension portions

134a, 134b, 134c, 134 d. The features of these extensions 134 will be described herein. One of ordinary skill in the art will appreciate that any of the features described herein with respect to one embodiment of the spacer pad 130 may be provided in any other embodiment.

As shown in fig. 4 to 8, the extension portions 134 protrude outward from their respective central portions 132 at regular intervals. As shown in fig. 4 and 6, the regular intervals may be about every 45 °. As shown in fig. 8, the regular intervals may be about every 90 °.

As shown in fig. 6 and 7, the extension portion 134b of the spacer pad 130b has an end portion 136 b. The width of the end portion 136b is greater than the width of the remaining portion of the corresponding extension 134 b. The wider end portion 136b of the spacer pad 130b may be desirable to provide a larger base for the absorbent pad 150. The wide end portions 136b may be made wide enough so that the end portions 136b of adjacent extension portions 134b overlap each other when the spacer pad 130b is positioned within the helmet shell.

Further, as shown in fig. 6 and 7, a spacer pad 130b may be included in the liner 137. The liner 137 may be configured to surround the spacer pad 130b to provide comfortable contact between a user and the spacer pad 130 b.

As shown in fig. 8, the extension portions 134c may be axially symmetrically arranged with respect to the central portion 132 c. Alternatively, as shown in fig. 4, the extension portions 134a may be axially asymmetrically arranged. Further, as shown in fig. 4, the extension portions 134a may have different lengths protruding from the central portion 132 a.

The shape and size of the

extensions

134a, 134b, 134c may also depend on the configuration of the helmet shell 110, as described below.

As shown in fig. 5 and 7, the different lengths of the extensions 134 may be selected to correspond to the peripheral contour of the helmet shell 110. In other words, if the circumference of the helmet shell 110 has a different contour, the length of the extensions 134 may be selected such that the end of each extension 134 protrudes within a specified distance of the circumference of the helmet shell 110 when the spacer pad 130 is coupled to the helmet shell 110. In an exemplary embodiment, the extension 134 protrudes to within 0.125 inches to 2.0 inches of the perimeter of the helmet shell 110.

Helmet shell 110 may include features that would interfere with the path of extension 134. Accordingly, as shown in fig. 6 and 7, the extension 134b can be shaped to eliminate interference features in the helmet shell 110, i.e., by changing direction. As shown in fig. 6, at least one of the extension portions 134b may have a first portion 138 extending in a first direction and a second portion 139 extending from the first portion 138 in a second direction different from the first direction. This may desirably ensure that the entire length of the extension 134b adheres to the interior of the helmet shell 110.

Further, as shown in fig. 13, the spacer pad 130d may be designed for a baseball cap with a rear cutout (e.g., for accessing an adjustable strap). In this embodiment, one of the extensions 134d may be shortened and have rounded edges relative to the other extensions. The extension may be positioned to extend toward the rear cutout of the baseball cap. This feature may be desirable to allow all of the spacer pads 130d to fit comfortably within the baseball cap.

The width and number of extensions 134 may be selected based on the circumference and size of the helmet shell 110. As shown in fig. 4 and 6, the spacer pad 130 may include a relatively large number of thin extensions 134. Alternatively, as shown in FIG. 8, the spacer pads 130 may include a relatively small number of coarse extensions 134. In an exemplary embodiment, the width of the extension 134 is about 1 "to about 4".

It should be understood that the number, shape and size of the extensions 134 in fig. 4-8 are for illustrative purposes only and are not intended to be limiting. As will be understood by those of ordinary skill in the art in view of the description herein, spacer pads 130 having a different number of extensions 134 or different shapes and sizes of extensions 134 may be used without departing from the scope of the present invention.

Fig. 9A-9D illustrate an exemplary impact resistant pad 200 according to aspects of the present invention. Impact resistant pad 200 may be worn by a user as part of a protective headgear system during athletic activities such as wrestling. As a general overview, impact resistant pad 200 includes a top portion 220 and

side portions

240 and 250. Additional details of the impact resistant pad 200 are described herein.

The top portion 220 is configured to be positioned over the top of a user's head. As shown in fig. 9A-9D, the top portion 220 may be approximately circular and sized to cover substantially the entire top of a user's head. In the exemplary embodiment, top portion 220 includes a plurality of openings 222. During use of impact resistant pad 200, opening 222 desirably provides ventilation to the head of the user. As shown in fig. 9D, an opening 222 is formed around the periphery of the top portion 220.

Side portions

240 and 250 extend downward from top portion 220. As used herein, the term "side portion" is not intended to mean that the

portions

240 and 250 are located on the "sides" of the user's head (as opposed to the front or back). Rather, the

portions

240 and 250 may be located on either side of the user's head. As shown in fig. 9B and 9C, the

side portions

240 and 250 cover the front and rear portions of the user's head, respectively. As further illustrated in fig. 9A, the rear portion 250 extends a greater distance from the top portion 220 than the front portion 240. This may be desirable to provide better protection to the back of the user's head and to prevent blocking the user's view.

As shown in fig. 9A, the

side portions

240 and 250 are not directly connected to each other. In particular, a circumferential gap 260 is formed between side portion 240 and side portion 250. This may be particularly desirable so that impact resistant pad 200 may be worn by users having different head sizes. For example, when the user has a relatively small head, the gap 260 will be relatively narrow and the

side portions

240 and 250 will be in a position close to (or possibly in contact with) each other when placed on the user's head. However, when the user has a relatively large head, the gap 260 will be relatively large, and the

side portions

240 and 250 will be positioned away from each other when placed on the user's head.

It should be understood that the number, shape and size of the

side portions

240 and 250 in fig. 9A-9D are for illustrative purposes only and are not intended to be limiting. As will be understood by those of ordinary skill in the art in view of the description herein, different numbers or different shapes or sizes of the

side portions

240 and 250 may be used without departing from the scope of the present invention. Impact resistant pad 200 is formed from substantially the same materials as described above with respect to spacer pad 130.

Impact resistant pad 200 is not attached to any supporting structure. As will be discussed in further detail herein, impact resistant pad 200 is configured to be worn under a helmet. For this reason, the impact resistant pad 200 is desirably thin. In an exemplary embodiment, impact resistant pad 200 has a thickness of no greater than about 23mm, and even more preferably, no greater than about 3 mm. The thickness of impact resistant pad 200 may be selected based on a variety of factors including, for example, the type of helmet, the level of impact protection desired, and the type of material surrounding the pad (such as moisture wicking material, water wicking material, cloth, or neoprene).

Fig. 10A-10C illustrate an exemplary protective headgear system 300 according to aspects of the present invention. The protective headgear system 300 can be worn by a user during a sporting event such as a wrestling game. As a general overview, the protective headgear system 300 includes an impact resistant liner 320 and a helmet 340. Additional details of the protective headgear system 300 are described herein.

Impact resistant pad 320 is formed of a material designed to dissipate impact forces on the user's head. In the exemplary embodiment, impact resistant pad 320 is an impact resistant pad substantially as described above with respect to impact resistant pad 200. In particular, impact resistant pad 320 includes a top portion 322 and

side portions

324 and 325, top portion 322 being configured to be positioned over the top of a user's head, and

side portions

324 and 325 extending downward from top portion 322.

Side portions

324 and 325 are not directly connected to each other, but rather a circumferential gap (not shown) is defined between

side portions

324 and 325.

The helmet 340 is configured to be positioned on the impact resistant pad 320 over the head of a user. The helmet 340 is not connected to the impact resistant pad 320. When the helmet 340 is positioned over the impact-resistant pad 320, the helmet 340 covers a circumferential portion of the impact-resistant pad 320. In an exemplary embodiment, the helmet 340 includes a conventional wrestling helmet, as shown in fig. 10A to 10C. The helmet 340 includes a plurality of straps 342 for securing the helmet 340 to the head of a user. Strap 342 extends over top portion 322 of impact resistant pad 320. Impact resistant pad 320 may include a guide portion (not shown) for receiving and properly positioning strap 342 of helmet 340.

Those of ordinary skill in the art will appreciate that the helmet 340 is not limited to the embodiment shown in fig. 10A-10C. Fig. 11 illustrates another exemplary protective headgear system 400 according to aspects of the present invention. As a general overview, the protective headgear system 400 includes an impact resistant liner 420 and a helmet shell 440, as shown in fig. 11. The helmet shell 440 is configured to completely cover the head of a user. This may be desirable to provide an additional impact resistant layer on top of the impact resistant liner 420. The dimensions of the helmet shell 440 are selected such that the helmet 440 can receive the impact resistant liner 420 therein while still being securely positioned on the user's head. In an exemplary embodiment, the helmet shell 440 is a helmet shell substantially as described with respect to helmet shell 110. One of ordinary skill in the art will be aware of a suitable helmet shell 440 for use with the present invention in view of the description herein.

Fig. 12 illustrates an exemplary helmet padding system 500 in accordance with aspects of the present invention. Fig. 12 illustrates an exploded cross-sectional view of the helmet padding system 500 taken through a central portion thereof. Helmet liner system 500 may also be worn by a user during athletic activities. As a general overview, the system 500 includes a helmet shell 510, a spacing liner 530, and a deflection layer 570. Additional details of the system 500 are described herein.

The helmet shell 510 is configured to be positioned on the head of a user. Helmet shell 510 may be a helmet shell substantially as described with respect to helmet shell 110, or may be a helmet substantially as described above with respect to helmet 340. The dimensions of the helmet shell 510 are selected such that the helmet shell 510 can accommodate the remaining components of the system 500 while still being securely positioned on the user's head.

The spacer 530 is positioned inside the helmet shell 510. The spacer pads 530 may be spacer pads substantially as described with respect to the spacer pads 130. Alternatively, spacer pads 530 may be impact resistant pads substantially as described above with respect to impact resistant pad 200. Likewise, spacer pads 530 may be formed of any material as described above with respect to spacer pads 130 or impact resistant pads 200, and may take any shape as described above with respect to spacer pads 130 and/or impact resistant pads 200. Alternatively, the spacing pad 530 may have any other shape suitable for covering the space between the user's head and the helmet shell 510. The spacer pad 530 may also include a series of raised portions 531 as described above with respect to raised portions 131 formed on a surface of the spacer pad 530.

The spacer 530 is not adapted to be coupled to the inside of the helmet shell 510. In other words, the spacing pad 530 remains unconnected to the helmet shell 510 (or from any other component connected to the helmet shell 510, for example, a conventional helmet pad provided with the helmet shell 510). This enables relative movement between the spacer pads 530 and the helmet shell 510, which may be important to help dissipate forces from impacts, as described in further detail below with respect to the deflection layer 570.

Helmet liner system 500 can include a plurality of absorbent pads 550 coupled to spacer pads 530. The absorbent pad 550 may be substantially the same as described above with respect to the absorbent pad 150.

The deflection layer 570 is positioned between the helmet shell 510 and the spacing liner 530. The deflection layer 570 is formed of a less flexible (i.e., stiffer) material than the spacing pad 530. This causes the hard surface of the deflection layer 570 to deflect a portion of the impact force along the surface of the deflection layer 570 rather than transferring the force through the deflection layer 570 to the spacer pad 530. In other words, the deflection layer 570 helps to convert the impact force into a tangential force (propagating along the surface), rather than a normal force (propagating through the surface to the user's head). In an exemplary embodiment, the deflection layer 570 comprises a sheet of polycarbonate material. The deflection layer 570 may have a shape corresponding to the shape of the spacing pad 530 such that the deflection layer 570 completely covers the space between the spacing pad 530 and the helmet shell 510.

The deflection layer 570 is also not coupled to the interior of the helmet shell 510. This creates a "sliding plane" between the deflection layer 570 and the helmet shell 510 and enables relative motion between the two components. In other words, this allows for independent movement of the user's head (with the spacing pad 530 and the deflection layer 570 in contact with the user's head) and the helmet shell 510.

The helmet liner system 500 can also include a plurality of deflector plates 580. The deflection plate 580 may be coupled to the interior of the helmet shell 510 in a position such that the deflection plate 580 slidably abuts the deflection layer 570. The deflector 580 may be coupled to the helmet shell 510, for example, with an adhesive. The deflection plate 580 is formed of the same material as the deflection layer 570. The use of a deflection plate 580 coupled to the helmet shell 510 may further facilitate a sliding interface between the deflection layer 570 and the helmet shell 510, and thereby facilitate deflection of impact forces in a tangential direction along the deflection layer 570, rather than passing impact forces through the deflection layer 570 to the spacing pad 530.

The helmet padding system 500 can also include a deformation layer 590. The deformation layer 590 may be positioned between the deflection layer 570 and the spacer 530. The deformation layer 590 is configured to deform when subjected to a force resulting from an impact. The deformation layer 590 may undergo elastic (i.e., reversible) or plastic (i.e., irreversible) deformation. In an exemplary embodiment, the deformation layer 590 comprises a corrugated sheet of plastic material configured to undergo plastic deformation. As shown in fig. 12, the corrugated plastic sheet may include a pair of plastic surface layers separated by a plurality of plastic ridges defining an air gap between the pair of plastic surface layers. Similar to the deflection layer 570, the deformation layer 590 may have a shape corresponding to the shape of the spacer liner 530 such that the deformation layer 590 completely covers the space between the spacer liner 530 and the deflection layer 570.

The deformation layer 590 may undergo plastic deformation such as wrinkling, bending, breaking or other irreversible changes. Accordingly, after an impact to the helmet liner system 500, where such impact is sufficient to cause significant plastic deformation of the deformation layer 590, the deformation layer 590 may need to be periodically replaced.

The above-described components of helmet padding system 500 may be included in a liner (not shown). In particular, the liner may be configured to surround and house the spacer liner 530, the deflection layer 570, and the deformation layer 590 to maintain their relative positioning and arrangement. The liner may be formed, for example, from a cloth or nylon material to provide comfortable contact between the user and the components of the helmet padding system 500.

Fig. 14A-14D illustrate another example helmet padding system 600 according to aspects of the present disclosure. Helmet liner system 600 may be worn by a user during military activities, for example, under a standard military helmet. As a general overview, the system 600 includes a frame 610 and a spacer pad 630. Further details of the system 600 are described herein.

The frame 610 is configured to be positioned on the head of a user. The frame 610 comprises a rigid material such as, for example, a plastic or polycarbonate material. The dimensions of the frame 610 are selected so that the helmet shell 610 can accommodate the spacing pads 630 while still being securely positioned on the user's head.

Spacer pads 630 are coupled to the frame 610. Spacer pads 630 may be spacer pads substantially as described with respect to spacer pads 130, and/or may be formed of any of the materials described with respect to spacer pads 130. In particular, the spacer pads 630 include a central portion 632 and a plurality of extension portions 634 that project outwardly from the central portion 632. A plurality of extensions 634 are secured to the frame 610.

As shown in fig. 14A and 14B, each extension 630 has an end portion that is wider than the portion of the respective extension that is coupled to the central portion 632. Specifically, the extension portion 630 widens as the extension portion 630 extends outward from the central portion 632. An end portion of the extension portion 634 is fixed to the frame 610.

In an exemplary embodiment, the frame 610 includes a groove 612, as shown in fig. 14B. An end portion of each of the plurality of extension portions 634 is inserted within the recess 612. End portions of the plurality of extensions 634 may be further secured to the frame by one or more attachment mechanisms. Suitable attachment mechanisms 615 include, for example, rivets, adhesives, or stitching.

As shown in fig. 14D, the frame 610 may be configured to be coupled to a helmet. In an exemplary embodiment, the frame 610 is configured to be coupled to a standard type military helmet. A standard type military helmet includes a plurality (e.g., four) of pre-set mounting points, such as drilled holes, in the helmet. In this embodiment, the frame 610 includes a plurality of through holes 614 positioned to align with pre-set mounting points in the military helmet. This may desirably simplify the attachment of the frame 610 to the helmet. The spacing pad 630 is secured to the frame 610 in such a manner that it does not contact the helmet when the frame 610 is coupled to the helmet.

In an exemplary embodiment, the frame 610 has a ring shape, as shown in fig. 14B and 14C. A plurality of extension portions 634 extend upwardly from the frame 610 such that the central portion 623 is positioned above the frame 610. This creates a cavity within the frame 610 in which the top of the user's head is located during use.

Fig. 15A-15C illustrate another example helmet padding system 700 according to aspects of the present disclosure. The helmet padding system 700 is substantially identical to the helmet padding system 600, and only the differences between these two embodiments will be described below.

In an exemplary embodiment, the frame 710 of the helmet padding system 700 has a dome shape, as shown in fig. 15A to 15C. A standard type military helmet includes a plurality (e.g., four) of pre-set mounting points, such as drilled holes, in the helmet. In this embodiment, the frame 710 includes a plurality of through holes 714, the plurality of through holes 714 being positioned to align with pre-set mounting points in the military helmet.

A spacer 730 is positioned within the dome and may be adhered to the inner surface of the dome. The dome-shaped frame 710 includes a plurality of ridges 716 formed on an outer surface of the dome-shaped frame 710. As shown in fig. 15A and 15B, the ridge 716 extends along the frame 710 from edge to edge through the top portion of the frame 710. When the dome-shaped frame 710 is coupled to the helmet, the frame 710 contacts the helmet only along the outermost surface of the plurality of ridges 716. This may be desirable to minimize the transfer of impact forces from the helmet to the frame 710. In this embodiment, the frame 710 may also include a plurality of straps 718 for enhancing the fit and comfort of the system 700 when worn by the user, as shown in fig. 15C.

Helmet liner systems

600 and 700 may also include a deformation layer. The deformation layer may be a layer substantially as described with respect to deformation layer 590. In one embodiment, the deformation layer is positioned between the frame and the spacer pad. In an alternative embodiment, the deformation layer is positioned such that it is located between the frame and the helmet when the frame is coupled to the helmet.

As explained above with respect to fig. 13, the

helmet liner system

800, 900, 1000 of the present invention can be used with a baseball cap. In accordance with another aspect of the present invention, a helmet liner system is disclosed for use with such a baseball cap. New fig. 16 to 18 disclose an alternative embodiment of such a system.

The baseball cap of the system has the style of a normal baseball cap except for the two sides of the cap. The body of the cap may be formed of a flexible material such as cotton or a synthetic textile. The rear of the cap may be adapted to the user's head or may include a conventional adjustable strap. As shown in fig. 16, the sides 810 of the cap extend downward to cover at least a portion (preferably at least 50%) of the user's temples and the user's ears. Both sides of the cap form downwardly extending portions. The downwardly extending portion may extend across the rear of the cap as shown in fig. 16. Alternatively, as shown in fig. 17 and 18, the downwardly extending portion may terminate (or become narrower) across the rear of the cap. As shown in fig. 16, the cap body may include an opening 820 in the ear region of the user. An opening may be desirable in order to promote ventilation within the cap and provide better hearing for the user.

Within the cap, a spacer liner is provided. In an exemplary embodiment, a spacer pad 130d shown in fig. 13 is provided. Alternatively, the cap may include any of the spacing pads and accessory components described herein. In addition, the system may use conventional foam pads in place of spacer pads.

The shape of the spacer pad may be selected to maximize the coverage of the user's head while minimizing interference with the user's comfort (e.g., interfering with the user's hearing). In an exemplary embodiment, the spacer pad has one extension extending from the top of the cap to a position in front of the user's ear to cover the user's temple and another extension extending from the top of the cap to a position behind the user's ear to cover the base of the skull behind the user's ear. The spacer pad is shaped to leave a gap in the region of the user's ear to avoid interfering with the user's hearing.

To protect the region of the user's ears, the cap may include a rigid frame. The rigid frame may be formed, for example, from a rigid plastic. In an exemplary embodiment, the rigid frame includes a plurality of rigid outer members extending along the periphery of the gap (adjacent the edges of the spacer pads). The frame may have a substantially circular, rectangular or triangular shape. The frame also includes an open area between the rigid outer members. To avoid interfering with the hearing of the user, an open area in the central portion of the rigid frame is desirable.

The cap may also include a rigid liner around the periphery of the cap. In an exemplary embodiment, the rigid liner comprises a thin rigid structure extending around the peripheral edge of the cap. The rim may be formed of, for example, a rigid plastic. To enhance user comfort, the edges may be desirably positioned within folds or pockets of the outer cloth of the cap.

Fig. 19A and 19B illustrate an exemplary helmet padding system 1100 in accordance with aspects of the present invention. Helmet liner system 1100 may be worn by a user during athletic activities. Desirably, the helmet liner system 1100 can be worn under another piece of headgear, such as a baseball cap. As a general overview, the system 1100 includes a main portion 1110 and a removable portion 1180. Fig. 19A shows a view of the helmet liner system 1100 with the removable portion 1180 coupled to the main portion 1110, and fig. 19B shows a view of the helmet liner system with the removable portion 1180 separated from the main portion 1110. Additional details of the system 1100 are described herein.

When the system 1100 is worn under a baseball cap with a back cut (e.g., for an adjustable strap), the removable portion 1180 is desirably located at the same location as the back cut. In normal use, the removable portion 1180 remains coupled to the main portion 1110 and provides impact protection to the user in the area of the posterior incision in substantially the same manner as the main portion 1110. However, the user may also choose to remove the removable portion 1180 during use. Removing the removable portion 1180 from the main portion 1110 opens the area of the user's head directly under the cut-out of the baseball cap. This may be particularly desirable for users of the system 1100 with long hair because long hair users want their hair to pass through the space of the rear cut of the baseball cap for comfort or other reasons. In other words, removing the removable portion 1180 desirably allows some users to use the rear cutout of the baseball cap just as they would normally be if the helmet liner system were not worn under their baseball cap.

The main portion 1110 is configured to be positioned on a user's head. The main portion 1110 may include a number of different subcomponents similar to the layers of the various helmet liner systems described herein. In an exemplary embodiment, the main portion 1110 includes a spacer pad (not shown), a plurality of absorbing pads 1150, and a deflection layer 1170.

The spacer pads of the main portion 1110 are positioned inside the main portion 1110. The spacer pads may be spacer pads substantially as described with respect to spacer pad 130. Alternatively, the spacer pads may be impact resistant pads substantially as described above with respect to impact resistant pad 200. Likewise, the spacer pads may be formed of any of the materials described above with respect to spacer pads 130 or impact resistant pads 200, and may take any of the shapes described above with respect to spacer pads 130 and/or impact resistant pads 200.

In a particularly suitable embodiment, the spacer pads of the main portion 1110 have a shape and configuration corresponding to the spacer pads 130d shown in FIG. 13. As described above, both the system 1100 and the spacer pad 130d may be intended for use in a baseball cap having a back cut (e.g., for an adjustable strap). In this embodiment, the spacer pads of the main section 1110 have shortened extensions with rounded edges relative to the other extensions, as shown in FIG. 13. In the helmet liner system 1100, the extension portion is positioned to extend toward the location of the removable portion 1180 of the system 1100. Thus, the spacer pads of the main portion 1110 do not extend into or otherwise interfere with the area covered by the removable portion 1180. The system 1100 may also include a separate spacer pad of the same material coupled to the interior of the removable portion 1180.

The helmet liner system 1100 can include a plurality of absorbent pads 1150 coupled to a spacing pad and/or a deflection layer 1170. The absorbent pad 1150 may be substantially the same as described above with respect to the absorbent pad 150 (shown in fig. 1 and 3). As shown in fig. 19C, the system 1100 may include an absorbent pad 1150 on both the main portion 1110 and the removable portion 1180. One of ordinary skill in the art will appreciate that the number and location of the absorbent pads 1150 shown in fig. 19C are set forth for illustrative purposes and are not intended to be limiting.

The deflecting layer 1170 is positioned along the outside of the main portion 1110. The deflection layer 1170 may be a deflection layer substantially as described with respect to deflection layer 570 (shown in figure 12). In an exemplary embodiment, the deflecting layer 1170 is formed of a polycarbonate material. The deflection layer 1170 is shaped and sized so as to fit comfortably on a user's head while containing the components within (including the spacing pad and the absorbent pad 1150). The deflecting layer 1170 includes a cutout portion 1172 (similar to a spacer pad), the cutout portion 1172 having a shape corresponding to the shape of the back cutout of a conventional baseball cap. Cutout portion 1172 is sized to receive removable portion 1180 therein so as to form (with removable portion 1180) a generally continuous dome shape on the top of a user's head. The deflecting layer 1170 may also include one or more protruding sections 1174 to enhance the ability of the system 1100 to dissipate impact forces acting on a user's head.

The deflecting layer 1170 is not adapted to be coupled to the interior of a baseball cap. Like the deflection layer 570, this forms a "slip plane" between the deflection layer 570 and the baseball cap, and enables relative motion between the two components. In other words, this allows for independent movement of the user's head (with the spacer pads and deflecting layers 1170 in contact with the user's head) and the baseball cap.

The removable portion 1180 is configured to be coupled to the main portion 1110 and removable from the main portion 1110. The removable section 1180 may be formed of substantially the same material as the main section 1110. In particular, removable portion 1180 may include a spacer pad, an absorbent pad, and a deflection layer, which are the same components used to form main portion 1110. The removable portion 1180 is shaped to correspond to the shape of the back cut of a conventional baseball cap and is sized to be received by the cut-out portion 1172 of the deflecting layer 1170 of the main portion 1110.

The removable portion 1180 may be coupled to the main portion 1110 by a number of different mechanisms. In an exemplary embodiment, the removable portion 1180 is frictionally coupled to the main portion 1110, as shown in fig. 19A and 19B. In this embodiment, the removable portion 1180 includes a tab 1182 adapted to slide along an exterior surface of the main portion 1110 and a tab 1184 adapted to slide along an interior surface of the main portion 1110. The

tabs

1182 and 1184 sandwich the main portion 1110 therebetween, forming a friction fit that holds the removable portion 1180 in place against the main portion 1110.

Alternatively or additionally, the removable portion 1180 may be coupled to the main portion 1110 using one or more snap mechanisms, as shown in fig. 19C and 19D. In this embodiment, the removable portion 1180 includes a location of the protrusion 1186 that mates with a corresponding aperture 1188 on the main portion 1110. When the removable portion 1180 is properly positioned against the main portion 1110, the protrusion 1186 is received within the aperture 1188, thereby snapping the removable portion 1180 into place against the main portion 1110. The snap mechanism may be configured to frictionally retain the connection until a predetermined pressure is applied to un-snap the removable portion 1180 from the main portion 1110.

The above-described embodiments allow for decoupling and recoupling of the removable portion 1180 from the main portion 1110. However, in some embodiments, the removable portion 1180 may not be permanently recoupled to the main portion 1110. In one embodiment, the removable portion 1180 may be attached to the main portion by one or more pieces of weakened, thinned, or perforated material (e.g., the material of the deflecting layer 1170). The removable portion 1180 may then be permanently removed from the main portion 1110 by breaking this area of weakened material.

Fig. 20A and 20B illustrate an alternative embodiment 1200 of a helmet liner system 1100. As shown in fig. 20A and 20B, the deflection layer of the helmet liner system 1200 has a more streamlined outer surface without the protruding section of the system 1100. This may enable the helmet padding system 1200 to more easily fit within or under a baseball cap, as shown in fig. 21.

As shown in fig. 20B, the removable portion 1280 is frictionally coupled to the main portion 1210 by a plurality of outer surface tabs 1282 and a plurality of inner surface tabs 1284 adapted to slide along the inner surface of the main portion 1110. The

tabs

1282 and 1284 clamp the main portion 1210 therebetween, thereby forming a friction fit that holds the removable portion 1280 in place against the main portion 1210. When the system 1200 is used under a baseball cap having a back cut, the removable portion 1280 may optionally be removed to allow a user with long hairs to extend their hair through the back cut of the cap.

Fig. 22 and 23 illustrate another example helmet padding system 1300 according to aspects of the present disclosure. As with

systems

1100 and 1200, a user may wear the helmet liner system 1300 during athletic activities and, desirably, may wear under another piece of headgear, such as a baseball cap. In general, system 1300 includes the same components described above with respect to system 1100. Additional features forming part of system 1300 are set forth below.

The main portion 1310 of the system 1300 includes a buffer portion 1390. The cushioning portion 1390 extends into the cut-out region of the deflection layer 1370. In an exemplary embodiment, the buffer portion 1390 extends into the cutout region along the centerline of the deflecting layer 1370 from the foremost edge of the deflecting layer 1370 toward the rear of the deflecting layer 1370. Buffer section 1390 separates the opposing portions of deflection layer 1370 to enable one side of deflection layer 1370 to move relative to the other side of deflection layer 1370. Such movement may desirably assist the system 1300 in dissipating impact forces acting on the user's head.

The cushioning portion 1390 is formed of a material that is more flexible and/or more compressible than the material of the deflection layer 1370. In an exemplary embodiment, the buffering portion is formed of the same material as the

absorbent pad

150 or 1150.

The length of the cushioning portion 1390 may be adjusted to optimize the force dissipation effect provided. In one exemplary embodiment, the cushioning portion 1390 extends along the entire length of the deflection layer 1370 from the front-most edge to the rear edge of the cutout portion, as shown in fig. 22. In an alternative embodiment, the buffer section 1390 does not extend along the entire length of the deflection layer 1370, but terminates before the trailing edge, as shown in fig. 23. Further, the width of the cushioning portion 1390 may be adjusted to optimize the force dissipation effect provided. In an exemplary embodiment, the width across the cushioning portion 1390 may be about 0.3 inches to about 3.0 inches.

Fig. 24A-24C illustrate an exemplary helmet padding system 1400 according to aspects of the present invention. The helmet padding system 1400 may be worn by a user during athletic activities. Desirably, the helmet padding system 1400 can be worn under another piece of headgear, such as a baseball cap, a knit winter cap, a beanie, or other piece of aesthetic headgear. As a general overview, the system 1400 includes a rigid housing 1410 and a spacer 1440. Additional details of the system 1400 are described herein.

The rigid shell 1410 is configured to cover the top of the user's head. The rigid housing 1410 is sized to be worn under a baseball cap. Accordingly, it may be desirable for rigid housing 1410 to be formed from a thin, rigid material. In an exemplary embodiment, the rigid housing 1410 is formed of a polycarbonate material as described above with respect to the deflecting layer 1170. The material may have a thickness of less than about 5mm, and more desirably less than about 3.5 mm. Forming the rigid shell 1410 with a low profile (i.e., thin dimension) is desirable to facilitate use of the helmet padding system 1400 by eliminating conflicts with the aesthetic features of headgear (e.g., baseball cap) worn on top of the rigid shell 1410.

Rigid housing 1410 includes a body portion 1420 and a pair of side portions 1430. The body portion 1420 has a lower front edge 1421 extending between the pair of side portions 1430. When worn under a baseball cap, the lower front edge 1421 is positioned adjacent to the edge of the baseball cap. The body portion 1420 further includes a lower rear edge 1422 extending between the pair of side portions 1430 opposite the lower front edge 1421.

In one embodiment, the lower rear edge 1422 of the body portion 1420 has approximately the same height as the lower front edge 1421, as shown in FIG. 24A. In this embodiment, the lower rear edge extends along substantially the same circumferential line (around the head of the user) as the lower front edge 1421. In this embodiment, when the rigid housing 1410 is worn under a baseball cap (such as a fitted baseball cap), the lower rear edge 1422 is positioned adjacent to the lower edge of the cap.

In an alternative embodiment, the lower rear edge 1422 extends down the head of the user along with the side portions 1430, as shown in fig. 25 and 26. In this embodiment, the lower rear edge 1422 extends along substantially the same circumferential line as the lower edges of the side portions 1430. In this embodiment, when the rigid housing 1410 is worn under a baseball cap (such as a fitted baseball cap), the lower rear edge 1422 extends under the lower edge of the cap.

The body portion 1420 may include at least one opening in the body portion 1420. The opening preferably allows for breathability between the interior of the rigid shell 1410 (i.e., the area adjacent the user's head) and the exterior of the rigid shell 1410. In an exemplary embodiment, the body portion 1420 includes a plurality of openings 1423, wherein at least one opening is positioned between each side portion 1430 and an apex of the rigid housing 1410, as shown in fig. 24A.

The body portion 1420 may also include one or more ridges along its surface. In an exemplary embodiment, the body portion 1420 includes a raised ridge 1424, the raised ridge 1424 extending from an area adjacent the lower front edge 1421, across the apex of the body portion 1420, to an area adjacent the lower rear edge 1422, as shown in fig. 24C. The ridges 1424 may provide additional structural stability to the rigid housing 1410, allowing the housing 1410 to better dissipate impact forces. The ridges 1424 may also provide additional space between the rigid housing 1410 and the user's head, thereby increasing the comfort and breathability of the user.

As shown in fig. 24B, the body portion 1420 may also include a pair of cutouts 1425 on the ends of the front edge 1421. A cutout 1425 is provided between the front edge 1421 and the side portion 1430. As shown in fig. 24C, the body portion 1420 may also include a pair of cutouts 1425 on the ends of the rear edge 1422. Cutout 1425 desirably provides a path for coupling rigid housing 1410 to the interior of a baseball cap, as described below. Those of ordinary skill in the art will appreciate that the shape of the cutout 1425 shown in fig. 24B is provided for purposes of illustration, and is not limiting. For example, the cutout 1425 may be formed in a triangular or circular shape without departing from the scope of the present invention.

As shown in fig. 24A-24C, the side portions 1430 extend downwardly below a lower front edge 1421 of the body portion 1420. The side portions 1430 are sized to cover at least a portion (preferably at least 50%) of the user's ears when the user wears the rigid housing 1410. The side portions 1430 are also desirably sized to cover the user's temples when the user wears the rigid housing 1410. To this end, each side portion 1430 may have a circumferential length (along the side of the user's head) that is longer than the distance (or height) that the side portion 1430 extends below the lower front edge 1421.

The side portion 1430 may include at least one opening in the side portion 1430. The opening may preferably be positioned above the ear of the user when the rigid housing 1410 is worn by the user. This positioning allows the user to hear ambient sounds while maintaining protection of the user's ear region from impact. In the exemplary embodiment, each side portion 1430 includes a set of spaced apart elongated openings 1431, as shown in fig. 24A.

The side portions 1430 may also include one or more expansion portions. In an exemplary embodiment, the side portion 1430 includes an extension 1432 that extends outwardly relative to a surface of the body portion 1420, as shown in fig. 24C. The extensions 1432 may provide additional space between the rigid housing 1410 and the user's head and ears, thereby increasing the comfort of the user. When the rigid housing 1410 is worn under a baseball cap, the extension portion 1432 can include all of the side portions 1430 that are positioned under the baseball cap.

The side portions 1430 may also include one or more attachment points. During use of the helmet padding system 1400, one or more accessories (such as straps, goggles, headphones, or other accessories) may need to be attached to the system 1400. Accordingly, rigid housing 1410 may include one or more attachment points designed to facilitate attachment of an appropriate accessory to a user's athletic activity. These attachment points are preferably located on the side portions 1430 so that they are accessible even when the rigid shell 1410 is worn under a baseball cap. In an exemplary embodiment, the side portion 1430 includes a pair of through holes 1433 on either end thereof, as shown in fig. 24A. The through-hole 1433 provides an attachment point for a strap (e.g., chin strap) that attaches to the rigid housing 1410.

Spacer 1440 is positioned inside rigid shell 1410 as shown in fig. 27. The spacer pads may be spacer pads substantially as described with respect to spacer pad 130. Alternatively, the spacer pads may be impact resistant pads substantially as described above with respect to impact resistant pad 200. Likewise, the spacer pads may be formed of any of the materials described above with respect to spacer pads 130 or impact resistant pads 200, and may take any of the shapes described above with respect to spacer pads 130 and/or impact resistant pads 200.

In a particularly suitable embodiment, the spacing pad 1440 includes a first portion 1441, the first portion 1441 extending circumferentially around a lower portion of the rigid shell 1410, e.g., adjacent to the lower front edge 1421 and the lower rear edge 1422, as shown in fig. 27. In this embodiment, the spacing pad 1440 includes a second portion 1442, the second portion 1442 extending from an area adjacent the lower forward edge 1421, across the apex of the body portion 1420, to an area adjacent the lower rearward edge 1422.

In the case where the helmet padding system 1400 is used with a fitted baseball cap, the rigid shell 1410 may have a continuous uninterrupted rear body portion. However, when the helmet padding system 1400 is used with an adjustable baseball cap, the rigid shell 1410 may include cutouts as shown in fig. 24A-26 and described below.

Rigid housing 1410 may include a cutout 1426 in an area of body portion 1420 opposite lower front edge 1421. When the rigid housing 1410 is worn under a baseball cap, the cutout 1426 is disposed in the area of the body portion 1420 adjacent the rear of the baseball cap. In this embodiment, the baseball cap may be an adjustable baseball cap having an opening for receiving an adjustable strap. Thus, the cutout 1426 has a shape that corresponds to the shape of the opening in the rear of the adjustable baseball cap.

When the rigid shell 1410 incorporates a cutout 1426, the helmet liner system 1400 may also include a removable portion 1460 configured to fit within the cutout 1426 of the rigid shell 1410. The removable portion 1460 is formed of the same material as the rigid housing 1410 in order to provide similar protection from impact forces. Thus, when the removable portion 1460 is coupled to the rigid housing 1410, these components form an approximately continuous dome shape on the top of the user's head.

Both the cutout 1426 and the removable portion 1460 may have shapes different from the semi-circular cutout shape shown in fig. 25. For example, as shown in fig. 26, the cutout 1426 and the removable portion 1460 may cover a significantly larger portion of the body portion 1420 of the rigid housing 1410. It may be desirable to provide a larger cutout 1426 and removable portion 1460 in order to provide size or profile adjustability for rigid housing 1410 to accommodate users with heads of different sizes.

The removable portion 1460 is configured to be coupled to the rigid housing 1410 and removable from the rigid housing 1410. Removable portion 1460 may be coupled to rigid housing 1410 by a number of different mechanisms as described above with respect to removable portion 1180. In an exemplary embodiment, the removable portion 1460 is frictionally coupled to the rigid housing 1410, as shown in fig. 24C. In this embodiment, the removable portion 1460 includes tabs 1461 adapted to slide along an outer surface of the rigid housing 1410 and tabs 1462 adapted to slide along an inner surface of the rigid housing 1410, as shown in fig. 25. The

tabs

1461 and 1462 sandwich the rigid housing 1410 between them, thereby creating a friction fit that holds the removable portion 1460 in place against the rigid housing 1410. Removable portion 1460 may be coupled to rigid housing 1410 using alternative mechanisms as described above with respect to removable portion 1180.

Where rigid housing 1410 does not include a cutout as described above, body portion 1420 may include one or more slits in its lower portion to accommodate users with heads of different sizes. The inclusion of slits in the rigid housing 1410 may allow for adjustability in size between opposing sides of the body portion 1420 without opening gaps that may adversely affect the protection provided by the rigid housing 1410. In an exemplary embodiment, the body portion 1420 includes a vertical slit 1427, the vertical slit 1427 extending upward from the lower rear edge 1422 at approximately the midpoint of the rear portion of the body portion 1420, as shown in fig. 28A. In another exemplary embodiment, the body portion 1420 includes a J-shaped slot 1428 along a rear portion of the body portion 1420, as shown in fig. 28B. As shown in fig. 28A and 28B, the body portion 1420 may include a tab 1429 on one side of the

slot

1427 or 1428, the tab 1429 extending above the surface of the body portion on the other side of the

slot

1427 or 1428. The tabs 1429 desirably allow opposing sides of the body portion 142 to move circumferentially relative to one another (depending on the size of the user's head) while preventing opposing sides of the body portion 1420 from moving relatively inward or outward.

As shown in fig. 29, the helmet padding system 1400 may also include a baseball cap 1480. Baseball cap 1480 has a body portion 1481 and a bill portion 1482. As described above, rigid housing 1410 is configured to be worn under baseball cap 1480. Side portions 1430 of rigid housing 1410 are configured to extend downward below the lower edge of body portion 1481 of baseball cap 1480, as shown in fig. 29. In this embodiment, the side portions 1430 provide protection for the head of the user below the lower edge of the conventional baseball cap, including the user's temples and ears that are not normally covered by the conventional baseball cap.

In addition, the extension of the side portions 1430 below the lower edge of the baseball cap 1480 provides a visual indication to others that the user is wearing implements that increase head protection relative to the head protection provided by a conventional baseball cap. Such visual indication may be useful, for example, to facilitate compliance with head protection requirements during athletic activities.

Baseball cap 1480 may include an inner material flap adjacent to its front or rear lower edge. Such a flap of material may be used to provide a connection between baseball cap 1480 and rigid housing 1410. In an exemplary embodiment, the body portion 1420 may also include a pair of cutouts 1425, as shown in fig. 24B. In this embodiment, a tab on baseball cap 1480 passes through cutout 1425 such that a portion of the tab is positioned adjacent to the inner surface of rigid housing 1410 (as opposed to the exterior of rigid housing 1410). The portion of the folding flap that passes through cutout 1425 may be used to secure baseball cap 1480 to rigid housing 1410 and provide additional comfort and/or sweat absorption for the user's forehead.

Fig. 30A and 30B illustrate an alternative embodiment 1500 of a helmet padding system 1200 according to aspects of the present invention. Helmet padding system 1500 may be worn by a user during athletic activities. Like helmet padding system 1200, helmet padding system 1500 may be worn under another piece of headgear, such as a baseball cap. As a general overview, the system 1500 includes a main portion 1510 and an opening 1580. Helmet padding system 1500 includes substantially the same features as helmet padding system 1100 and/or 1200, except as described herein.

The main portion 1510 is configured to be positioned on the head of a user. The main portion 1510 may include a number of different subcomponents corresponding to the layers of the various helmet liner systems described herein. In an exemplary embodiment, the main portion 1510 includes a spacer pad, a plurality of absorbent pads, and a deflection layer. Other components or layouts for dissipating impact forces may be selected based on the various embodiments described herein.

As shown in fig. 30B, the main portion 1510 of the helmet padding system 1500 has a streamlined outer surface similar in design to the helmet padding system 1200. This streamlined outer surface can enable helmet padding system 1500 to more easily fit within or under a baseball cap, as described above. The streamlined outer surface may include one or more raised ridges 1512 extending along its surface. As shown in fig. 30B, the raised ridge 1512 extends in a direction from the front of the user's head to the back of the user's head. These ridges provide additional structural support to the main portion 1510 and help dissipate impact forces acting on the user's head.

Unlike

systems

1100 and 1200, the opening 1580 of the helmet padding system 1500 does not extend down to the lower edge of the main portion 1510. Instead, the main portion 1510 includes a bridge 1514 that extends below the opening 1580, as shown in fig. 30A and 30B. Thus, the opening 1580 is completely surrounded by portions of the main portion 1510. This arrangement improves the structural stability of helmet padding system 1500 by limiting the relative movement of the left and right sides of main portion 1510 with respect to each other. For example, the bridge 1514 may be formed from a substantially rigid material (e.g., the deflection layer material described above) to prevent inward and outward movement of the left and right sides of the main portion 1510 relative to each other.

The bridge 1514 also allows the helmet liner system 1500 to maintain a continuous uninterrupted lower edge, as shown in fig. 30B. The continuous lower edge may improve the protection and comfort of the user. Also, the bridge 1514 may include one or more internal liner layers as described herein to improve impact resistance. For example, the main portion 1510 of the helmet padding system 1500 may include a continuous padding layer along its entire lower circumferential edge to improve protection of the user from impact.

When the system 1500 is worn under a baseball cap having a back cut (e.g., for an adjustable strap), the opening 1580 is ideally located at the same location as the back cut. Thus, the opening 1580 exposes an area of the user's head directly under the cutout of the baseball cap. This may be particularly desirable for users of the system 1500 having long hair, because long hair users may wish their hair to extend through the back cut of the baseball cap for comfort or other reasons. In other words, the opening 1580 desirably allows some users to use the rear cutout of their baseball cap just as they would normally be if the helmet liner system were not worn under their baseball cap.

The system 1500 may also include a removable plate 1582 sized to fit within the opening 1580, as shown in fig. 31A-31C. The removable plate 1582 may have a generally elliptical shape corresponding to the shape of the opening 1580 so as to be easily received within the opening 1580 and fill the opening 1580. The removable panel 1582 provides impact protection to a user in the area of the opening 1580 in substantially the same manner as the main portion 1510 when received therein. To this end, the removable panel 1582 can be formed of the same material as the main portion 1510 of the system 1500 and can include one or more internal liner layers described herein to improve impact resistance.

When the removable plate 1582 is received in the opening 1580, the removable plate 1582 can be coupled to the main portion 1510 using any of the attachment methods described above with respect to the

removable portions

1180 and 1280. In an exemplary embodiment, the removable plate includes a plurality of snap mechanisms 1584 that snap onto the main portion 1510 of the system 1500, as shown in fig. 31C. The snap mechanism 1584 can snap onto the main portion 1510 on an outer surface of the main portion 1510 and/or on an inner surface of the main portion 1510. To this end, the snap mechanisms can be formed as tabs configured to extend along an outer or inner surface of the main portion 1510 when the removable plate 1582 is positioned within the opening 1580. The removable panel 1582 can then be removed from the main portion 1510 at the discretion of the user.

In an exemplary embodiment, the removable panel 1582 includes a pair of outer tabs 1586 that extend from an upper edge and an outer ridge 1588 that extends along a lower edge of the removable panel 1582. As shown in fig. 31A, the tabs 1586 and ridges 1588 are positioned to rest on or contact the outer surface of the main portion 1510. The removable panel 1582 further includes at least one inner tab 1589 that extends from the upper edge and is positioned to rest on or contact the inner surface of the main portion 1510. In this embodiment, to couple the removable plate 1582 to the main portion 1510, the plate 1582 is slid into the opening 1580 at a small angle to sandwich the main portion 1510 between the tabs 1586 and the tabs 1589 and allow the ridges 1588 to rest on the lower edge of the opening 1580, as shown in fig. 31C.

Fig. 32A and 32B illustrate an alternative embodiment 1600 of a helmet padding system 1400 according to aspects of the present invention. Helmet liner system 1600 may be worn by a user during athletic activities. Like the helmet liner system 1400, the helmet liner system 1600 can be worn under another piece of headgear, such as a baseball cap. As a general overview, the system 1600 includes a rigid housing 1610, a spacer pad, and a mask 1690. The helmet padding system 1600 also includes substantially the same features as the helmet padding system 1400, except as described herein.

Rigid housing 1610 is configured to cover the top of a user's head. The rigid housing 1610 is sized to be worn under a baseball cap. Rigid housing 1610 includes a body portion 1620 and a pair of side portions 1630. Body portion 1620 has a lower front edge 1621 extending between the pair of side portions 1630. Body portion 1620 also includes a lower rear edge 1622 extending between the pair of side portions 1630 opposite lower front edge 1621.

When worn under a baseball cap, the lower front edge 1621 extends under the bill of the baseball cap. In an exemplary embodiment, the lower front edge 1621 of the rigid housing 1610 extends approximately one inch below the bill of the baseball cap. This protruding lower front edge 1621 may be desirable so as to provide additional protection for the user and provide a location for attaching the face mask 1690, as will be discussed below.

As shown in fig. 32A, lower rear edge 1622 of body portion 1620 extends down the head of the user along with side portions 1630. In this embodiment, lower rear edge 1622 extends along substantially the same circumferential line as the lower edge of side portion 1630. In this embodiment, when the rigid housing 1610 is worn under a baseball cap (such as a fitted baseball cap), the lower rear edge 1622 extends under the lower edge of the cap to provide additional protection to the neck of the user.

Body portion 1620 may also include a pair of notches 1625 on the ends of front edge 1621, one notch of the pair of notches 1625 being shown in fig. 32B. A cutout 1625 is disposed between front edge 1621 and side portion 1630. Those of ordinary skill in the art will appreciate that the shape of the notch 1625 shown in fig. 24B is provided for purposes of illustration, and not limitation.

As shown in fig. 32A and 32B, side portion 1630 extends downward below lower front edge 1621 of body portion 1620. Side portion 1630 is sized to cover at least a portion of a user's ear (preferably at least 50%) when rigid housing 1610 is worn by the user. Side portions 1630 are also desirably sized to cover the user's temples when the user is wearing rigid housing 1610.

Side portion 1630 may also include one or more attachment points. These attachment points are designed to facilitate the attachment of a suitable accessory to the user's physical activity. These attachment points are preferably positioned on the side portions 1630 so that they are accessible even when the rigid housing 1610 is worn under a baseball cap.

In an exemplary embodiment, side portion 1630 includes one or more grooves 1631. The recess 1631 provides an attachment point for the face shield 1690 to couple to the rigid housing 1610. In a preferred embodiment, the lower front edge 1621 also includes one or more grooves 1631 for coupling the mask 1690 to the rigid housing 1610. As described above, since the lower front edge 1621 extends below the lower edge of the visor, the groove 1631 on the lower front edge 1621 can access the face mask 1690 without removing the user's cap.

In another exemplary embodiment, side portion 1630 includes one or more snaps 1633. The clasp 1633 provides an attachment point for a strap (e.g., chin strap) to be attached to the rigid housing 1610. The catch 1633 may move within a slot on the side section 1630 to adjust the fit of the chin strap.

Rigid housing 1610 may include a cutout 1626 in an area of body portion 1620 opposite lower front edge 1621. When the rigid housing 1610 incorporates the cut-out 1626, the helmet liner system 1600 may further include a removable portion 1660, the removable portion 1660 configured to fit within the cut-out 1626 of the rigid housing 1610. The removable portion 1660 is formed of the same material as the rigid housing 1610 in order to provide similar protection from impact forces.

The face mask 1690 is configured to protect the user's face from impacts or projectiles (such as baseball or softball) that are typically performed during athletic activities. The mask 1690 may be permanently coupled to the rigid housing 1610 or may be removably coupled to the rigid housing 1610. Preferably, the face shield 1690 is removable from the rigid housing 1610 without removing the rigid housing 1610 from the user's head and without removing any components from the rigid housing 1610. In this manner, such a mask 1690 need not be worn all the way through the athletic activity, and the mask 1690 can be removed without removing the user's baseball cap or the rest of the system 1600 (e.g., when impact to the user's face is not likely to occur).

In an exemplary embodiment, the mask 1690 is formed from a plurality of rigid rods 1692 that protect the user's face without substantially obstructing the user's view. Rod 1692 may have the following: which are sized to mate with corresponding attachment points on the rigid housing 1610 to couple the mask 1690 to the rigid housing 1610. In a preferred embodiment, one or more portions of rod 1692 are sized to mate with corresponding grooves 1631 formed on side portions 1630 and/or lower front edge 1621. Groove 1631 is sized to provide a snug secure fit with the portion of rod 1692 while allowing mask 1690 to be removed (e.g., by sliding) from groove 1631 when mask 1690 is not in use.

System 1600 may also include chin strap 1694. Chin strap 1694 is configured to secure system 1600 to the head of a user during the course of athletic activity. Chin strap 1694 has ends that are coupled to respective side portions 1630 of rigid housing 1610, and chin strap 1694 is long enough to wrap under the chin of the user when rigid housing 1610 is worn by the user. Chin strap 1694 can be permanently coupled to rigid housing 1610 or can be removably coupled to rigid housing 1610. Preferably, chin strap 1694 can be removed from rigid housing 1610 without removing rigid housing 1610 from the user's head and without removing any components from rigid housing 1610. In this manner, the chin strap 1694 need not be worn at all times throughout the athletic activity, and the user's chin strap may be removed without moving the user's baseball cap or the rest of the system 1600 (e.g., when the user is not engaged in an active athletic activity).

In an exemplary embodiment, chin strap 1694 is formed of a flexible material, such as rubber or fabric, that is sufficiently pliable or soft to be comfortable for the user while maintaining sufficient strength to secure system 1600 to the user's head. Chin strap 1694 has a mating structure 1696, which mating structure 1696 is sized to mate with a corresponding attachment point on rigid housing 1610 in order to couple chin strap 1694 to rigid housing 1610. In a preferred embodiment, the mating structures 1696 are configured to snap into corresponding snaps 1633 formed on the side portions 1630 of the rigid housing 1610. The catch 1633 is configured to provide a snug secure connection to the mating structure 1696 on the chin strap 1694. The catch 1633 may also be positioned in a slot on the side section 1630 to allow adjustment of the chin strap 1694 to ensure comfort and safety for the user.

Fig. 33A-35 illustrate an exemplary helmet padding system 1700 according to aspects of the present disclosure. Helmet padding system 1700 may be worn by a user during athletic activities. Desirably, helmet padding system 1700 can be worn under another piece of headgear, such as a baseball cap, a knit winter cap, a beanie cap, or other piece of aesthetic headgear. As a general overview, system 1700 includes a rigid housing 1710 and a spacer 1740. Additional details of the system 1700 are described herein.

Rigid housing 1710 is configured to cover the top of a user's head. Rigid housing 1710 is sized to be worn under a baseball cap. Accordingly, it may be desirable for rigid housing 1710 to be formed from a thin, rigid material. In an exemplary embodiment, rigid housing 1710 is formed from a polycarbonate material, as described above. The material may have a thickness of less than about 5mm, and more desirably less than about 3.5 mm. Forming rigid shell 1710 with a low profile (i.e., thin dimension) is desirable to facilitate use of helmet padding system 1700 by eliminating conflicts with the aesthetic features of headgear (e.g., baseball cap) worn on top of rigid shell 1710.

Rigid housing 1710 includes a body portion 1720 and a pair of side portions 1730. Body portion 1720 has a lower front edge 1721 that extends between the pair of side portions 1730. When worn under a baseball cap, the lower front edge 1721 is positioned adjacent to the bill of the baseball cap. Body portion 1720 also includes a lower rear edge 1722 extending between the pair of side portions 1730 opposite lower front edge 1721.

In one embodiment, lower rear edge 1722 of body portion 1720 has approximately the same height as lower front edge 1721, as shown in FIG. 33A. In this embodiment, the lower rear edge extends along substantially the same circumferential line (around the head of the user) as the lower front edge 1721. In this embodiment, when rigid housing 1710 is worn under a baseball cap (e.g., a fitted baseball cap), lower rear edge 1722 is positioned adjacent to a lower edge of the cap.

Body portion 1720 may include at least one slot in body portion 1729. The slot may preferably assist the ability of rigid housing 1710 to protect against impact forces, for example, by allowing portions of rigid housing 1710 to move relative to one another. The slot also preferably allows for breathability between the interior of rigid housing 1710 (i.e., the area adjacent the user's head) and the exterior of rigid housing 1710.

In an exemplary embodiment, body portion 1720 of rigid housing 1710 includes a pair of slots 1723, with the pair of slots 1723 positioned between each side portion 1730 and an apex of rigid housing 1710. As shown in fig. 33B and 34, slots 1723 are positioned on either side of the apex of rigid housing 1710. The pair of slots 1723 are configured to extend in a direction from a rear of the user's head to a front of the user's head when the rigid housing 1710 is worn on the user's head.

Body portion 1720 may also include one or more ridges along a surface of body portion 1720. In an exemplary embodiment, body portion 1720 includes raised ridges 1724, where raised ridges 1724 extend from a region adjacent lower leading edge 1721, across the apex of body portion 1720, to a region adjacent lower trailing edge 1722, as shown in FIG. 33B. Ridges 1724 may provide additional structural stability to rigid housing 1710, allowing housing 1710 to better dissipate impact forces. Ridges 1724 may also provide additional space between rigid housing 1710 and the user's head, thereby increasing the comfort and breathability of the user. In this embodiment, the pair of slots 1723 are positioned on either side of the ridge 1724.

Side portions 1730 extend downward below lower front edge 1721 and lower rear edge 1722 of body portion 1720, as shown in FIG. 33A. Side portions 1730 are sized to cover at least a portion of a user's ear (preferably at least 50%) when the user wears rigid housing 1710. Side portions 1730 are also desirably sized to cover the user's temples when the user wears rigid housing 1710. In an exemplary embodiment, each side portion 1730 has a pair of sidewalls that extend downward from body portion 1720 at an angle that is perpendicular to lower front edge 1721 and lower rear edge 1722 of body portion 1720. Further, as shown in fig. 33A, each side portion 1730 may have a rectangular shape.

Spacer 1740 is positioned inside rigid housing 1710 as shown in fig. 35. The spacer pads 1740 may be spacer pads substantially as described with respect to the spacer pads 130. Alternatively, spacer liner 1740 may be an impact resistant liner substantially as described above with respect to impact resistant liner 200. Likewise, the spacer pads may be formed of any of the materials set forth above with respect to spacer pads 130 or impact resistant pads 200, and may take any of the shapes described above with respect to spacer pads 130 and/or impact resistant pads 200.

In a particularly suitable embodiment, spacer 1740 includes a first portion 1741 that extends circumferentially around a lower portion of rigid housing 1710, as shown in fig. 35. In this embodiment, the spacer 1740 includes a second portion 1742 positioned between the slots 1723, as set forth in more detail below.

In the case where helmet padding system 1700 is used with an fitted baseball cap, rigid shell 1710 can have a continuous uninterrupted rear body portion. However, when the helmet padding system 1700 is used with an adjustable baseball cap, the rigid shell 1710 may include cutouts as shown in fig. 33A-33B and described below.

Rigid housing 1710 may include a cutout 1726 in an area of body portion 1720 opposite lower forward edge 1721. When rigid housing 1710 is worn under a baseball cap, cutout 1726 is provided in the area of body portion 1720 adjacent the rear of the baseball cap. In this embodiment, the baseball cap may be an adjustable baseball cap having an opening for receiving an adjustable strap. Thus, the cutout 1726 has a shape that corresponds to the shape of the opening in the rear of the adjustable baseball cap.

When rigid shell 1710 incorporates cut-out 1726, helmet padding system 1700 can also include a removable portion 1760 configured to fit within cut-out 1726 of rigid shell 1710. Removable portion 1760 is formed of the same material as rigid housing 1710 in order to provide similar protection from impact forces. Thus, when removable portion 1760 is coupled to rigid housing 1710, these components form an approximately continuous dome shape on top of the user's head. Removable portion 1760 is configured to be coupled to rigid housing 1710 and is removable from rigid housing 1710. Removable portion 1760 may be coupled to rigid housing 1710 through a variety of different mechanisms as described above with respect to

removable portion

1180 or 1460.

When rigid housing 1710 incorporates cut-out 1726, both slot 1723 and ridge 1724 may extend to cut-out 1726. Likewise, a second portion 1742 of the spacer 1740 may be coupled to the interior of the ridge 1724 between the slot 1723 and the adjacent cut-out 1726.

Fig. 36A-38 illustrate another exemplary helmet padding system 1800 according to aspects of the present invention. Helmet padding system 1800 may be worn by a user during athletic activities. Desirably, helmet padding system 1800 can be worn under another piece of headgear, such as a baseball cap, a stocking cap, a beanie, or other piece of aesthetic headgear. As a general overview, system 1800 includes a rigid housing 1810 and a spacer pad 1840. Additional details of system 1800 are described herein.

The rigid shell 1810 is configured to cover at least a portion of the top of a user's head. The rigid housing 1810 is sized to be worn under a baseball cap. Accordingly, it may be desirable for rigid housing 1810 to be formed from a thin, rigid material. In an exemplary embodiment, rigid housing 1810 is formed from a polycarbonate material, as described above. The material may have a thickness of less than about 5mm, and more desirably less than about 3.5 mm. Forming the rigid shell 1810 with a low profile (i.e., thin dimension) is desirable to facilitate use of the helmet padding system 1800 by eliminating conflicts with the aesthetic features of headgear (e.g., baseball cap) worn on top of the rigid shell 1810.

The rigid housing 1810 includes a body portion 1820 having a lower forward edge 1821. When worn under a baseball cap, the lower front edge 1821 is positioned adjacent to the bill of the baseball cap. The body portion 1820 also includes a rear edge 1822 opposite the lower front edge 1821. In one embodiment, the rear edge 1822 of the body portion 1820 is positioned about the middle of the user's head, as shown in fig. 36A. In this embodiment, the rear edge 1822 may be generally positioned in a plane that bisects the user's head in an up-down direction.

The body portion 1820 may include at least one slot in the body portion 1820. The slots may preferably assist the ability of the rigid shell 1810 to protect against impact forces, for example, by allowing portions of the rigid shell 1810 to move relative to one another. The slots also preferably allow for breathability between the interior of the rigid shell 1810 (i.e., the area adjacent the user's head) and the exterior of the rigid shell 1810.

In an exemplary embodiment, body portion 1820 of rigid shell 1810 includes a pair of slots 1823 positioned on either side of the apex of rigid shell 1810, as shown in fig. 36B and 37. The pair of slots 1823 are configured to extend in a direction from a rear of the user's head to a front of the user's head when the rigid housing 1710 is worn on the user's head.

The body portion 1820 may also include one or more ridges along a surface of the body portion 1820. In an exemplary embodiment, the body portion 1820 includes a raised ridge 1824, the raised ridge 1824 extending from a region adjacent the lower leading edge 1821, across the apex of the body portion 1820, to a region adjacent the trailing edge 1822, as shown in fig. 36B. Ridges 1824 may provide additional structural stability to rigid housing 1810, allowing housing 1810 to better dissipate impact forces. The ridges 1824 may also provide additional space between the rigid shell 1810 and the user's head, thereby increasing the comfort and breathability of the user. In this embodiment, the pair of slots 1823 are positioned on either side of a ridge 1824.

Spacer liner 1840 is positioned inside rigid housing 1810 as shown in fig. 37 and 38. The spacer pads 1840 may be spacer pads substantially as described with respect to the spacer pads 130. Alternatively, spacer pad 1840 may be an impact resistant pad substantially as described above with respect to impact resistant pad 200. Likewise, the spacer pads may be formed of any of the materials described above with respect to spacer pads 130 or impact resistant pads 200, and may take any of the shapes described above with respect to spacer pads 130 and/or impact resistant pads 200.

In a particularly suitable embodiment, spacer liner 1840 includes a first portion 1841 that extends circumferentially around a lower portion of rigid housing 1810, as shown in fig. 37. In this embodiment, spacer pad 1840 includes second portions 1842 positioned between slots 1823. A second portion 1842 of the spacer pad 1840 may be coupled to an interior of the ridge 1824 between the slot 1823 and the adjacent back edge 1822.

As shown in fig. 38, when the rigid shell 1810 is worn under a baseball cap (e.g., a fitted baseball cap), the rear edge 1822 is positioned at or immediately behind the apex of the baseball cap. In other words, the rigid shell 1810 is positioned between the baseball cap and the user's head at a front portion of the user's head, while the rigid shell 1810 is not positioned between the baseball cap and the user's head at a rear portion of the user's head. Such a configuration may increase the comfort of a user wearing the helmet padding system 1800 while still maintaining protection for portions of the front portion of the user's head that are more likely to be impacted.

Fig. 39A-39C illustrate an exemplary helmet padding system 1900 according to aspects of the present disclosure. Wearing helmet liner system 1900 may be worn by a user during athletic activities. Desirably, helmet liner system 1900 may be worn under another piece of headgear, such as a football helmet, a baseball cap, a knit winter cap, a beanie, or other piece of aesthetic headgear. As a general overview, the system 1900 includes a rigid housing 1910 and a spacer insert 1940. Additional details of the system 1900 are described herein.

The rigid housing 1910 is configured to cover the top of a user's head. The rigid shell 1910 is sized to be worn within a football helmet between the padding of the football helmet and the wearer's head. Accordingly, it may be desirable for rigid housing 1910 to be formed from a thin, rigid material. In an exemplary embodiment, rigid housing 1910 is formed of a polycarbonate material, as described above. The material may have a thickness of less than about 5mm, and more desirably less than about 3.5 mm.

Rigid housing 1910 includes a body portion 1920. The body portion 1920 has a lower front edge 1921, lower side edges 1922 and a lower rear edge 1923. In one embodiment, the lower side edge 1922 of the body portion 1920 has substantially the same height as the lower front edge 1921. In this embodiment, the lower side edges 1922 extend along substantially the same circumferential line (around the head of the user) as the lower front edge 1921.

Lower back edge 1923 may be formed by a cut in the area of body portion 1920 opposite lower front edge 1921, as shown in fig. 39B. The cut-out may have an approximately semi-circular shape, or may have any other shape desired.

Alternatively, lower back edge 1923 may extend along substantially the same circumferential line (around the user's head) as lower front edge 1921 and lower side edges 1922, as shown in fig. 40A and 40B. In this embodiment, lower front edge 1921, lower side edge 1922, and lower rear edge 1923 all lie in the same plane.

The body portion 1920 may include at least one slot therein. The slots may preferably assist the ability of the rigid housing 1910 to protect against impact forces, for example by allowing portions of the rigid housing 1910 to move relative to each other. The at least one slot also preferably allows for breathability between the interior of the rigid housing 1910 (i.e., the area adjacent the user's head) and the exterior of the rigid housing 1910.

In the exemplary embodiment, body portion 1920 of rigid housing 1910 includes a first pair of slots 1924 and a second pair of slots 1925.

Slots

1924 and 1925 extend parallel to an apex line of rigid housing 1910 that extends in a direction of body portion 1920 from a forward-most point to a rearward-most point (as shown by the dashed lines in fig. 39A). As shown in fig. 39A,

slots

1924 and 1925 are positioned on either side of the apex line of rigid housing 1910, between the apex line and lower side edge 1922 of body portion 1920.

A slot 1924 extends from a lower front edge 1921 of the body portion 1920. As shown in fig. 39A, slot 1924 may extend to a point forward of a midpoint of body portion 1920, which is a line extending from one side of rigid housing 1910 to the other equidistant from a forward-most point to a rearward-most point of body portion 1920 (as shown in dotted lines in fig. 39A). Alternatively, slot 1924 may extend to a point closer to lower front edge 1921 than to the midpoint of body portion 1920, as shown in fig. 40A. In other embodiments, the slot 1924 may extend to a midpoint of the body portion 1920, or to a point behind the midpoint of the body portion 1920.

A slot 1925 extends from a lower rear edge 1923 of the body portion 1920. As shown in fig. 39A, the slot 1925 may extend to a point rearward of the midpoint of the body portion 1920. Alternatively, slot 1925 may extend to a point forward of the midpoint of body portion 1920, as shown in fig. 40A. In other embodiments, slot 1925 may extend to a midpoint of body portion 1920.

As shown in fig. 39A and 40A, the width of the slot 1925 may be greater than the width of the slot 1924. In other embodiments,

slots

1924 and 1925 may have the same width, or the width of slot 1924 may be greater than the width of slot 1925.

As shown in fig. 39A and 40A, the slots 1925 may have a gradually changing width while the slots 1924 have a constant width. In other embodiments, the slots 1924 and/or 1925 may have a constant or gradually varying width. Likewise, slots 1924 and/or 1925 may be progressively larger or smaller, i.e., may be larger as slots 1924 and/or 1925 extend away from their respective edges, or may be smaller as slots 1924 and/or 1925 extend away from their respective edges.

As shown in fig. 39A and 40A, the slot 1925 is positioned closer to the apex line of the rigid housing 1910 than the slot 1924. In other embodiments,

slots

1924 and 1925 may be positioned the same distance from the apex line of rigid housing 1910 or slot 1924 may be positioned closer to the apex line than slot 1925.

The variable length of the slot 1925 and the variable position of the lower rear edge 1923 allow the rigid material of the housing 1910 to form a flexible tab extending from the apex of the rigid housing 1910 down to the lower rear edge 1923. The flexible tongue enables helmet padding system 1900 to accommodate users of various head sizes, and also allows for greater comfort for the user and greater protection for all portions of the user's head, including the back of the user's head.

The body portion 1920 may also include one or more ridges along a surface of the body portion 1920. In an exemplary embodiment, body portion 1920 includes a first ridge 1926 extending along a vertex line of rigid housing 1910 and a pair of second ridges 1927 extending along both sides of ridge 1926, as shown in fig. 39A. The

ridges

1926 and 1927 may provide additional structural stability to the rigid housing 1910, allowing the housing 1910 to better dissipate impact forces. The

ridges

1926 and 1927 may also provide additional space between the rigid housing 1910 and the user's head, thereby increasing the comfort and breathability of the user.

As shown in fig. 39A, a portion of the ridge 1927 may be interrupted or removed to form a slot 1925. In other embodiments, the

ridges

1926 and 1927 may be interrupted between the lower front edge 1921 and the lower rear edge 1923 of the body portion 1920, or a portion of the ridge 1926 and/or a portion of the ridge 1927 may be removed to form the slot 1924.

Spacer 1940 is positioned inside rigid housing 1910 as shown in fig. 39C. The spacer pad 1940 may be a spacer pad substantially as described with respect to spacer pad 130. Alternatively, spacer liner 1940 may be an impact resistant liner substantially as described above with respect to impact resistant liner 200. Likewise, the spacer pads may be formed of any of the materials described above with respect to spacer pads 130 or impact resistant pads 200, and may take any of the shapes described above with respect to spacer pads 130 and/or impact resistant pads 200.

In an exemplary embodiment, spacer pad 1940 includes a first portion 1941 that extends circumferentially around a lower portion of rigid housing 1910 and a second portion 1942 that is positioned between slots 1925, as shown in fig. 39C.

A first portion 1941 of the spacer pads 1940 is interrupted by the slots 1924 and thus forms a separate portion that follows the lower front edge 1921 and lower side edges 1922 of the body portion 1920. Although the interruption is caused by the slot 1924, the first portion 1941 of the spacer pad 1940 can follow a majority (e.g., 50% or more, 60% or more, 70% or more, 80% or more, or 90% or more) of the circumference of the lower front edge 1921 and lower side edge 1922, as shown in fig. 39C.

A second portion 1942 of the spacer pads 1940 extend between the slots 1925 along an apex line of the body portion 1920. The second portion 1942 can cover a majority (e.g., 50% or more, 60% or more, 70% or more, 80% or more, or 90% or more) of the space between the slots 1925, as shown in fig. 39C.

The spacer liner 1940 may also include one or more third portions 1943 that contact the first portion 1941. The third portion 1943 covers the space between the first portion 1941 and the slot 1925, as shown in fig. 39C.

Fig. 41A-41C illustrate an exemplary helmet padding system 2000 in accordance with aspects of the present invention. Helmet padding system 2000 may be worn by a user during athletic activities. Desirably, helmet padding system 2000 can be worn under another piece of headgear, such as a football helmet, a baseball cap, a knit winter cap, a beanie, or other piece of aesthetic headgear. As a general overview, the system 2000 includes a rigid housing 2010 and a spacer pad 2040. Additional details of system 2000 are described herein.

The rigid shell 2010 is configured to cover the top of the user's head. The rigid housing 2010 is sized to be worn within a baseball cap, as shown in fig. 42. Accordingly, it may be desirable for the rigid housing 2010 to be formed from a thin, rigid material. In an exemplary embodiment, as described above, rigid housing 2010 is formed from a polycarbonate material. The material may have a thickness of less than about 5mm, and more desirably less than about 3.5 mm.

Rigid housing 2010 includes a body portion 2020. The body portion 2020 has a lower front edge 2021, a lower side edge 2022, and a lower rear edge 2023. In one embodiment, the lower side edge 2022 of the body portion 2020 has substantially the same height as the lower front edge 2021. In this embodiment, the lower side edge 2022 extends along substantially the same circumferential line (around the head of the user) as the lower front edge 2021. As shown in fig. 42, when the rigid shell 2010 is worn under a baseball cap, the lower front edge 2021 and the lower side edge 2022 may be tucked into the sweatband of the baseball cap, i.e., between the outer material of the cap and the sweatband. This configuration may improve the comfort of the user wearing the rigid housing 2010.

The lower rear edge 2023 may extend along substantially the same circumferential line (around the head of the user) as the lower front edge 2021 and the lower side edge 2022. Alternatively, as shown in fig. 41B, lower rear edge 2023 may be formed by a cut-out located in an area of body portion 2020 opposite lower front edge 2021. The cutout may have an approximately semicircular shape as shown in fig. 41B, or may have any other shape as desired.

Body portion 2020 may include at least one slot in body portion 2020. The slots may preferably assist the ability of the rigid shell 2010 to protect against impact forces, for example by allowing portions of the rigid shell 2010 to move relative to one another. The at least one slot also preferably allows for breathability between the interior of the rigid shell 2010 (i.e., the area adjacent the user's head) and the exterior of the rigid shell 2010.

In an exemplary embodiment, the body portion 2020 of the rigid housing 2010 includes a pair of slots 2025. Slot 2025 extends parallel to an apex line of rigid housing 2010, which extends in a direction from a forward-most point to a rearward-most point of body portion 2020 (shown in dashed lines in fig. 41A). As shown in fig. 41A, the slot 2025 is positioned on either side of the apex line of the rigid shell 2010, between the apex line and the lower side edge 2022 of the body portion 2020.

A slot 2025 extends from a lower rear edge 2023 of the body portion 2020. As shown in fig. 41A, slot 2025 may extend to a point forward of a midpoint of body portion 2020, the midpoint being a line extending from one side of rigid housing 2010 to the other equidistant from a forward-most point to a rearward-most point of body portion 2020 (shown in dotted lines in fig. 41A). In other embodiments, slot 2025 may extend to a midpoint of body portion 2020, or to a point rearward of the midpoint of body portion 2020.

As shown in fig. 41A, the slot 2025 may have a gradually changing width. In other embodiments, the slot 2025 may be constant. Likewise, the slot 2025 may be progressively larger or smaller, i.e., the slot 2025 may be larger as it extends away from the lower rear edge 2023, or may be smaller as it extends away from the lower rear edge 2023.

Body portion 2020 may also include one or more ridges along its surface. In an exemplary embodiment, the body portion 2020 includes a ridge 2026 extending along a vertex line of the rigid shell 2010, as shown in fig. 41A. The ridges 2026 may provide additional structural stability to the rigid housing 2010, allowing the housing 2010 to better dissipate impact forces. The ridge 2026 may also provide additional space between the rigid shell 2010 and the user's head, thereby increasing the comfort and breathability of the user. As shown in fig. 41A, the slot 2025 is positioned on both sides of the ridge 2026.

The spacer pads 2040 are positioned inside the rigid shell 2010, as shown in fig. 41C. The spacer pads 2040 may be spacer pads substantially as described with respect to spacer pads 130. Alternatively, the spacer pads 2040 may be impact resistant pads substantially as described above with respect to impact resistant pad 200. Likewise, the spacer pads may be formed of any of the materials described above with respect to spacer pads 130 or impact resistant pads 200, and may take any of the shapes described above with respect to spacer pads 130 and/or impact resistant pads 200.

In an exemplary embodiment, the spacer pads 2040 include a first portion 2041 that extends circumferentially around a lower portion of the rigid shell 2010, and a second portion 2042 that is positioned between the slots 2025, as shown in fig. 41C.

The first portion 2041 of the spacing pad 2040 may follow a majority (e.g., 50% or more, 60% or more, 70% or more, 80% or more, or 90% or more) of the circumference of the lower front edge 2021 and the lower side edge 2022, as shown in fig. 41C. The second portion 2042 of the spacer 2040 extends between the slots 2025 along the apex line of the body portion 2020. The second portion 2042 can cover a majority (e.g., 50% or more, 60% or more, 70% or more, 80% or more, or 90% or more) of the space between the slots 2015, as shown in fig. 41C.

The spacer pads 2040 may also include one or more third portions 2043 that contact the first portion 2041. The third portion 2043 covers the space between the first portion 2041 and the slot 2025, as shown in fig. 41C.

Fig. 43A-43C illustrate another example helmet padding system 2100 according to aspects of the present disclosure. The helmet padding system 2100 may be worn by a user during athletic activities. Desirably, the helmet padding system 2100 may be worn under another piece of headgear, such as a baseball cap, a stocking cap, a beanie cap, or other piece of aesthetic headgear. As a general overview, the system 2100 includes a rigid housing 2110 and spacer pads 2140. Additional details of the system 2100 are described herein.

Rigid housing 2110 is configured to cover at least a portion of a user's head. The rigid housing 2110 is sized to be worn under a baseball cap. Accordingly, it may be desirable for rigid housing 2110 to be formed of a thin, rigid material. In an exemplary embodiment, rigid housing 2110 is formed of a polycarbonate material, as described above. The material may have a thickness of less than about 5mm, and more desirably less than about 3.5 mm. Forming the rigid shell 2110 with a low profile (i.e., thin dimension) is desirable to facilitate use of the helmet padding system 2100 by eliminating conflicts with the aesthetic features of headgear (e.g., baseball cap) worn on top of the rigid shell 2110.

The rigid housing 2110 includes a body portion 2120, the body portion 2120 having a lower edge 2121 and an upper edge 2123 opposite the lower edge 2121. When worn under a baseball cap, the lower edge 2121 is positioned adjacent to the bill of the baseball cap. The lower edge 2121 extends around less than the entirety of the user's head. In an exemplary embodiment, the lower edge 2121 extends around no more than half of the user's head. In this embodiment, the upper edge 2123 of the body portion 2120 is positioned near the middle of the user's head. In this embodiment, the upper edge 2123 can be positioned substantially within a plane that bisects the user's head in an up-down direction.

The body portion 2120 may include at least one slot in the body portion 2120. The slots may preferably assist the ability of the rigid housing 2110 to protect against impact forces, for example by allowing portions of the rigid housing 2110 to move relative to each other. The slots also preferably allow for breathability between the interior of the rigid housing 2110 (i.e., the area adjacent the user's head) and the exterior of the rigid housing 2110.

In an exemplary embodiment, the body portion 2120 of the rigid housing 2110 includes a pair of slots 2125, the pair of slots 2125 being positioned on either side of an apex line of the rigid housing 2110 that extends in a direction of the body portion 2120 from a forward-most point to a rearward-most point (shown in dashed lines in fig. 43A). The pair of slots 2125 are configured to extend in a direction of the apex line from the upper edge 2123 toward the lower edge 2121.

The body portion 2120 may also include one or more ridges along its surface. In an exemplary embodiment, the body portion 2120 includes a raised ridge 2126 that extends along the apex line, as shown in fig. 43A. The ridges 2126 may provide additional structural stability to the rigid housing 2110, allowing the housing 2110 to better dissipate impact forces. The ridges 2126 may also provide additional space between the rigid housing 2110 and the user's head, thereby increasing the comfort and breathability of the user. In this embodiment, the pair of slots 2125 are positioned on either side of the ridge 2126.

Spacer pads 2140 are positioned inside rigid housing 2110 as shown in fig. 43C and 44. The spacer pads 2140 may be spacer pads substantially as described with respect to the spacer pads 130. Alternatively, spacer pads 2140 may be impact resistant pads substantially as described above with respect to impact resistant pad 200. Likewise, the spacer pads may be formed of any of the materials set forth above with respect to spacer pads 130 or impact resistant pads 200, and may take any of the shapes described above with respect to spacer pads 130 and/or impact resistant pads 200.

In an exemplary embodiment, spacer pad 2140 includes a first portion 2141 that extends circumferentially around a lower portion of rigid housing 2110, as shown in fig. 43C. In this embodiment, the spacer pad 2140 includes a second portion 2142 positioned between the slots 2125. The second portion 2142 of the spacer pad 2140 may be coupled to the interior of the ridge 2126 between the slot 2125 and the adjacent upper edge 2123.

As shown in fig. 44, when the rigid housing 2110 is worn under a baseball cap (such as a fitted baseball cap), the upper edge 2123 is positioned at or immediately behind the apex of the baseball cap. In other words, the rigid housing 2110 is positioned at the front of the user's head between the baseball cap and the user's head, and the rigid housing 2110 is not positioned at the back of the user's head between the baseball cap and the user's head. Such a configuration may improve the comfort of a user wearing the helmet padding system 2100 while still maintaining protection for portions of the front portion of the user's head that are more likely to be impacted.

As shown in fig. 44, when the rigid shell 2110 is worn under a baseball cap, the lower edge 2121 may be tucked into the sweat band of the baseball cap, i.e., between the outer material of the cap and the sweat band. This configuration may improve the comfort of the user when wearing the rigid housing 2110.

Fig. 45A-45C illustrate another exemplary helmet liner system 2200 in accordance with aspects of the present disclosure. Helmet liner system 2200 can be worn by a user during athletic activities. Desirably, the helmet liner system 2200 can be worn under another piece of headgear, such as a baseball cap, a knit winter cap, a beanie cap, or other piece of aesthetic headgear. As a general overview, system 2200 includes a rigid housing 2210 and a spacer 2240. Additional details of the system 2200 are described herein.

Rigid housing 2210 is configured to cover at least a portion of a user's head. The rigid housing 2210 is sized to be worn under a baseball cap. Accordingly, it may be desirable for the rigid housing 2210 to be formed of a thin, rigid material. In an exemplary embodiment, the rigid housing 2210 is formed of a polycarbonate material as described above. The thickness of the material may be less than about 5mm, and more desirably less than about 3.5 mm. Forming the rigid housing 2210 with a low profile (i.e., thin dimension) is desirable to facilitate use of the helmet padding system 2200 by eliminating conflicts with the aesthetic features of headgear (e.g., baseball cap) worn on top of the rigid housing 2210.

The rigid housing 2210 includes a body portion 2220 having a lower edge 2221 and an upper edge 2223 opposite the lower edge 2221. When worn under a baseball cap, lower edge 2221 is positioned adjacent to the bill of the baseball cap. The lower edge 2221 extends around less than the entirety of the user's head. In an exemplary embodiment, lower edge 2221 extends around no more than half of the user's head. In this embodiment, the upper edge 2223 of the body portion 2220 is positioned at approximately the top of the user's forehead.

Upper edge 2223 extends along a line that is substantially parallel to lower edge 2221, or in a plane that is substantially parallel to the plane of lower edge 2221. Upper edge 2223 may be maintained a predetermined distance from lower edge 2221, such as a distance from one inch to four inches. As shown in fig. 45C, the upper edge 2223 and the lower edge 2221 are connected by a pair of curved ends 2222.

The body portion 2220 has a generally arcuate shape that is designed to closely follow the contour of the user's forehead, as shown in fig. 45B. In an exemplary embodiment, the body portion 2220 is sized and shaped to extend from an area covering one of the user's temples across the forehead of the user to an area covering another of the user's temples.

The body portion 2220 may include one or more ridges along a surface of the body portion 2220. In an exemplary embodiment, the body portion 2220 includes a raised ridge 2226 that extends from a lower edge 2221 to an upper edge 2223, as shown in fig. 45A. The ridges 2226 may provide additional structural stability to the rigid housing 2210, allowing the housing 2210 to better dissipate impact forces. The ridges 2226 may also provide additional space between the rigid housing 2210 and the user's head, thereby increasing comfort and breathability for the user.

Spacer pads 2240 are positioned inside rigid housing 2210 as shown in fig. 45C and 46. The spacer pads 2240 may be spacer pads substantially as described with respect to the spacer pads 130. Alternatively, spacer pad 2240 may be an impact resistant pad substantially as described above with respect to impact resistant pad 200. Likewise, the spacer pads may be formed of any of the materials set forth above with respect to spacer pads 130 or impact resistant pads 200, and may take any of the shapes described above with respect to spacer pads 130 and/or impact resistant pads 200.

In an exemplary embodiment, the spacer pads 2240 extend circumferentially between the lower edge 2221 and the upper edge 2223, as shown in fig. 45C. The spacing pads 2240 may cover a majority (e.g., 50% or more, 60% or more, 70% or more, 80% or more, or 90% or more) of the interior of the body portion 2220, as shown in fig. 45C.

As shown in fig. 46, when the rigid housing 2210 is worn under a baseball cap (such as a fitted baseball cap), the rigid housing 2210 does not cover the top or rear of the user's head. In other words, the rigid housing 2210 is positioned only at the front of the user's head between the baseball cap and the user's head. Such a configuration may improve the comfort of a user wearing the helmet padding system 2200 while still maintaining protection for portions of the front portion of the user's head that are more likely to be impacted.

As shown in fig. 46, when the rigid housing 2210 is worn under a baseball cap, the lower edge 2221 can be tucked into the sweat band of the baseball cap, i.e., between the outer material of the cap and the sweat band. This configuration may improve the comfort of the user wearing the rigid housing 2210.

Fig. 47A-47D illustrate an exemplary helmet padding system 2300 according to aspects of the present disclosure. Helmet liner system 2300 may be worn by a user during athletic activities. Desirably, helmet liner system 2300 can be worn under another piece of headgear, such as a baseball cap, a knit winter cap, a beanie cap, or other piece of aesthetic headgear. As a general overview, system 2300 includes a rigid housing 2310, spacer pads 2340, and straps 2370. Additional details of the system 2300 are described herein.

The rigid housing 2310 is configured to cover the top of the user's head. The rigid housing 2310 is sized to be worn within another piece of headgear. Accordingly, it may be desirable for the rigid housing 2310 to be formed of a thin, rigid material. In an exemplary embodiment, rigid housing 2310 is formed of a polycarbonate material as described above. The thickness of the material may be less than about 5mm, and more desirably less than about 3.5 mm.

The rigid housing 2310 includes a body portion 2320. The body portion 2320 has a lower front edge 2321, lower side edges 2322 and a lower rear edge 2323. In one embodiment, the lower side edge 2322 of the body portion 2320 has approximately the same height as the lower front edge 2321. In this embodiment, the lower side edge 2322 extends along substantially the same circumferential line (around the user's head) as the lower front edge 2321, as shown in fig. 47B.

The lower rear edge 2323 may extend along substantially the same circumferential line (around the user's head) as the lower front edge 2321 and the lower side edge 2322. Alternatively, as shown in fig. 47B, the lower rear edge 2323 may be formed by a cut-out in the body portion 2320 in an area opposite the lower front edge 2321 such that the lower rear edge 2323 is positioned in a different plane than the lower front edge 2321 and/or the lower side edges 2322.

In a particular embodiment, as shown in fig. 47B, the lower back edge 2323 may be defined by opposing end portions 2323a extending upwardly from the lower side edges 2322 and an intermediate portion 2323B extending to a point below the opposing portions. In this embodiment, the opposing end portions 2323a define a plane, and the intermediate portion 2323b is positioned outside of the plane. In other embodiments, the lower back edge 2323 may all be positioned in a single plane.

Body portion 2320 may include at least one slot in body portion 2320. The slots may preferably assist the ability of the rigid housing 2310 to protect against impact forces, such as by allowing portions of the rigid housing 2310 to move relative to each other. The at least one slot also preferably allows for breathability between the interior of the rigid housing 2310 (i.e., the area adjacent the user's head) and the exterior of the rigid housing 2310.

In an exemplary embodiment, the body portion 2320 of the rigid housing 2310 includes a pair of slots 2325. The slot 2325 extends parallel to an apex line of the rigid housing 2310 that extends in a direction from a forward-most point to a rearward-most point of the body portion 2320 (shown in dashed lines in fig. 47A). As shown in fig. 47A, the slot 2325 is positioned between the apex line and the lower side edge 2322 of the body portion 2320 on both sides of the apex line of the rigid housing 2310.

A slot 2325 extends from the lower rear edge 2323 of the body portion 2320. As shown in fig. 47A, the slot 2325 may extend to a point forward of a midpoint of the body portion 2320, the midpoint being a line extending from one side of the rigid housing 2310 to the other, equidistant from a forward-most point to a rearward-most point of the body portion 2320 (shown in dotted lines in fig. 47A). In other embodiments, the slot 2325 may extend to a midpoint of the body portion 2320, or to a point rearward of the midpoint of the body portion 2320.

As shown in fig. 47A, the slot 2325 may have a gradually changing width. In other embodiments, the slot 2325 may be constant. Likewise, the slot 2325 may become progressively larger or smaller, i.e., the slot 2325 may become larger as it extends away from the lower rear edge 2323, or the slot 2325 may become smaller as it extends away from the lower rear edge 2323.

Body portion 2320 may also include one or more raised ridges along a surface of body portion 2320. In an exemplary embodiment, the body portion 2320 includes a ridge 2326 extending along a line of vertices of the rigid housing 2310, as shown in fig. 47A. The ridge 2326 may provide additional structural stability to the rigid housing 2310, allowing the housing 2310 to better dissipate impact forces. The ridge 2326 may also provide additional space between the rigid housing 2310 and the user's head, thereby increasing comfort and breathability for the user. As shown in fig. 47A, the slots 2325 are positioned on both sides of the ridge 2326.

Spacing pad 2340 is positioned within rigid housing 2310 as shown in fig. 47C. Spacer pads 2340 may be spacer pads substantially as described with respect to spacer pads 130. Alternatively, spacer pads 2340 may be impact resistant pads substantially as described above with respect to impact resistant pad 200. Likewise, spacer pads 130 may be formed from any of the materials set forth above with respect to spacer pads 130 or impact resistant pads 200, and may take any of the shapes described above with respect to spacer pads 130 and/or impact resistant pads 200.

In an exemplary embodiment, the spacing pad 2340 includes a first portion 2341 extending circumferentially around a lower portion of the rigid housing 2310, and a second portion 2342 positioned between the slots 2325, as shown in fig. 47C and 47D, where fig. 47D is a cross-sectional view showing an interior half of the helmet pad system 2300.

The first portion 2341 of the spacer 2340 may follow a majority (e.g., 50% or more, 60% or more, 70% or more, 80% or more, or 90% or more) of the circumference of the lower front edge 2321 and the lower side edge 2322, as shown in fig. 47C. A second portion 2342 of the spacer 2340 extends between the slots 2325 along the apex line of the body portion 2320. The second portion 2342 may cover a majority (e.g., 50% or more, 60% or more, 70% or more, 80% or more, or 90% or more) of the space between the slots 2325, as shown in fig. 47C.

Spacer pads 2340 may also include one or more third portions 2343 in contact with first portion 2341. The third portion 2343 covers the space between the first portion 2341 and the slot 2325, as shown in fig. 47C and 47D.

Straps 2370 are attached to respective sides of rigid housing 2310. In an exemplary embodiment, a first strap portion 2370a extends downwardly from a front portion of each lower side edge 2322, and a second strap portion 2370b extends downwardly from a rear portion of each lower side edge 2322.

The first strap portion 2370a and the second strap portion 2370B may be joined to form a single strap that extends under the chin of the user, as shown in fig. 47B. Strap 2370 is of sufficient length to extend under the chin of a user when headgear padding system 2300 is worn by the user. The length of strap 2370 may be adjustable to accommodate users with different head sizes.

Strap 2370 includes one or more structures for attachment under the chin of a user to secure helmet padding system 2300 to the head of the user. Suitable structures will be apparent to those of ordinary skill in the art and may include, for example, buckles, or snaps.

Strap 2370 may be directly connected to rigid housing 2310 by, for example, bolts or snaps. As shown in fig. 47C and 47D, spacer 2340 may include one or more cutouts 2344 to facilitate connecting strap 2370 directly to rigid housing 2310.

Fig. 48A and 48B illustrate top and rear views, respectively, of an exemplary helmet padding system 2400 in accordance with aspects of the present invention. Helmet padding system 2400 may be worn by a user during athletic activities. Desirably, helmet padding system 2400 can be worn under another piece of headgear, such as a football helmet, a baseball cap, a knit winter cap, a beanie, or other piece of aesthetic headgear. As a general overview, system 2400 includes a rigid housing 2410 and a spacer pad (not shown). Additional details of system 2400 are described herein.

The rigid housing 2410 is configured to cover the top of the user's head. As shown with respect to helmet padding system 2000, rigid shell 2410 is sized to be worn within a baseball cap. Accordingly, it may be desirable for rigid housing 2410 to be formed of a thin, rigid material. In an exemplary embodiment, rigid housing 2410 is formed of a polycarbonate material as described above. The thickness of the material may be less than about 5mm, and more desirably less than about 3.5 mm.

The rigid housing 2410 includes a body portion 2420. The body portion 2420 has a lower front edge 2421, a lower side edge 2422 and a lower rear edge 2423. In one embodiment, the lower side edge 2422 of the body portion 2420 has a height that is substantially the same as the lower front edge 2421. In this embodiment, the lower side edge 2422 extends along substantially the same circumferential line (around the head of the user) as the lower front edge 2421.

The lower rear edge 2423 can extend along substantially the same circumferential line (around the head of the user) as the lower front edge 2421 and the lower side edge 2422. Alternatively, as shown in fig. 48B, the lower rear edge 2423 can be formed by a cutout in the body portion 2420 in an area opposite the lower front edge 2421. The cut-out may have any other shape desired.

The body portion 2420 can include at least one slot in the body portion 2420. The slots may preferably assist the ability of the rigid housing 2410 to protect against impact forces, for example, by allowing portions of the rigid housing 2410 to move relative to each other. The at least one slot also preferably allows for breathability between the interior of the rigid housing 2410 (i.e., the area adjacent the user's head) and the exterior of the rigid housing 2410.

In an exemplary embodiment, the body portion 2420 of the rigid housing 2410 includes a pair of slots 2425. Slot 2425 extends parallel to the apex line of rigid housing 2410. As shown in fig. 41A, the slot 2425 is positioned between the apex line and the lower side edge 2422 of the body portion 2420 on both sides of the apex line of the rigid housing 2410.

A slot 2425 extends from a lower rear edge 2423 of the body portion 2420. As shown in fig. 48A, the slot 2425 extends to a point forward of the midpoint of the body portion 2420. Slot 2425 may have a gradually changing width or may have a constant width. The slot 2425 can be progressively larger or smaller, i.e., the slot 2425 can be larger as it extends away from the lower rear edge 2423, or the slot 2425 can be smaller as it extends away from the lower rear edge 2423.

As shown in fig. 48A, slot 2425 defines a central portion 2470 of rigid housing 2410. The central portion 2470 extends along the apex line of the rigid housing 2410. Due to the presence of slot 2425, central portion 2470 is able to move relative to the side portions of rigid housing 2410.

In an exemplary embodiment, the central portion 2470 includes tabs 2472 on one or both sides of the central portion 2470. The tabs 2472 extend outwardly from the sides of the central portion 2470. The fins 2472 extend across the respective slots 2425 and overlap (i.e., cover) an area of the outer surface of the rigid housing 2410 on a side of each slot 2425 opposite the central portion 2470, as shown in fig. 48A and 48B. The tabs 2472 are not directly coupled to the side portions of the rigid housing 2410 such that the central portion 2470 remains movable relative to the side portions of the rigid housing 2410. Contact between the inner surface of the tabs 2472 and the outer surface of the side portions of the rigid housing 2410 may help to transfer and dissipate forces generated by impacts received at the central portion 2470 throughout the body of the rigid housing 2410.

In the exemplary embodiment, central portion 2470 includes a tail portion 2474 located at a rear end of central portion 2470. The tail portions 2474 extend outwardly from the ends of the central portion 2470 in one or both directions around the circumference of the rigid housing 2410. The tail 2474 is not directly coupled to the side portions of the rigid housing 2410 such that the central portion 2470 remains movable relative to the side portions of the rigid housing 2410. As shown in fig. 48B, the tail 2474 can define a lower rear edge 2423 of the body portion 2420.

Similar to the tabs 2472, the tail portions 2474 extend across the respective slots 2425 and overlap an area of the outer surface of the rigid housing 2410 on a side of each slot 2425 opposite the central portion 2470. Contact between the inner surface of the tail portion 2474 and the outer surface of the side portion of the rigid housing 2410 may help to transfer and dissipate forces generated by impacts received at the central portion 2470 throughout the body of the rigid housing 2410.

The tab 2472 and/or the tail 2474 may be formed of the same material as the rest of the rigid housing 2410, for example, formed of polycarbonate. The tab 2472 and/or the tail 2474 can be integrally formed (e.g., molded as one piece) with the remainder of the rigid housing 2410, or can be attached to the central portion 2470. The side portions of rigid housing 2410 may be provided with an impact resistant coating, such as an elastomeric coating, in the areas of contact with tabs 2472 and/or tail 2474 to facilitate dissipation of the forces generated by the impact on central portion 2470. The shape of the airfoil 2472 and/or tail 2474 in fig. 48A and 48B is not intended to be limiting. Rather, any shape may be used for the tabs 2472 and tails 2474 that overlap one or both side portions of the rigid housing 2410.

The spacer pads are positioned inside of rigid housing 2410. The spacer pads 2040 may be spacer pads incorporating any of the materials, geometries, or features described with respect to the spacer pads 2040.

Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention. In particular, any of the features described herein with respect to one embodiment may be provided in any other embodiment.

Claims

1. A helmet padding system comprising:

a rigid housing configured to cover a top of a user's head and to be worn under a piece of headgear, the rigid housing comprising a first pair of slots configured to extend in a direction from a rear of the user's head toward a front of the user's head when the rigid housing is worn on the user's head, the first pair of slots defining a central portion and opposing side portions of the rigid housing, the central portion comprising at least one flap extending from the central portion across one of the first pair of slots and covering a first area of one of the opposing side portions of the rigid housing; and

a spacer pad positioned within the rigid shell, the spacer pad comprising a layer of elastomeric material.

2. The helmet liner system of claim 1 wherein the first pair of slots are positioned on either side of an apex of the rigid shell.

3. The helmet liner system of claim 2 wherein the spacer pad comprises a portion coupled to the rigid shell between the first pair of slots.

4. The helmet liner system of claim 1 wherein the spacer liner comprises a portion extending circumferentially around at least a portion of a lower circumferential edge of the rigid shell.

5. The helmet liner system of claim 1, wherein a width of each slot of the first pair of slots increases in a direction from a rear of the user's head toward a front of the user's head.

6. The helmet padding system of claim 1, wherein the at least one flap is not directly coupled to one of the opposing side portions.

7. The helmet padding system of claim 1, wherein the at least one flap is integrally formed with the rigid shell.

8. The helmet padding system of claim 1, further comprising an impact-resistant coating positioned to cover the first area of one of the opposing side portions between the first area and the at least one flap.

9. The helmet padding system of claim 1, wherein the central portion comprises a pair of tabs, each tab of the pair of tabs extending from the central portion across a respective one of the first pair of slots and covering at least a portion of a respective one of the opposing side portions of the rigid shell.

10. The helmet padding system of claim 1, wherein the central portion further comprises a tail extending from the central portion across at least one slot of the first pair of slots and covering a second region of one of the opposing side portions of the rigid shell.

11. The helmet padding system of claim 10, wherein the tail is not directly coupled to one of the opposing side portions.

12. The helmet padding system of claim 10, wherein the tail is integrally formed with the rigid shell.

13. The helmet padding system of claim 10, further comprising an impact-resistant coating positioned to cover the second region of one of the opposing side portions between the second region and the tail.