KR20210071992A - Fiber Reinforced Impact Dissipating Liners and Methods for Making Fiber Reinforced Impact Dissipating Liners - Google Patents

Abstract

An impact dissipating liner (10, 140, 150), a helmet having an impact dissipating liner (355) and a method of making the impact dissipating liner are provided. The liner comprises a fluid impermeable enclosure (11, 141, 151) having a cavity (17, 147, 157) with sidewalls, a sheet of reinforced fabric (20, 120, 222) and a fluid (24, 242) contained within the enclosure. do. The enclosure 11 , 141 , 151 may have a central portion 236 and lobes 228 , 230 , 232 , 234 extending from the central portion, wherein the central portion and the lobes follow the shape of the inner surface of the helmet. is adjusted to Reinforcing sheets 20 , 120 , 222 may be made from a wide variety of materials and may provide improved structural support, structural integrity, and/or durability to the liner. Aspects of the present invention are adapted for use as head care; However, aspects of the present invention may be adapted to provide impact dissipation to any body part or surface.

Description

Fiber Reinforced Impact Dissipating Liners and Methods for Making Fiber Reinforced Impact Dissipating Liners

This application claims priority to pending U.S. Provisional Patent Application No. 62/742,869, filed on October 8, 2018, and to pending U.S. Provisional Patent Application, 62/893,647, filed August 29, 2019. This application also relates to co-pending US patent application 15/833,747, filed December 6, 2017. The entire disclosure of these applications is incorporated herein by reference.

Aspects of the present invention relate generally to protective barriers, such as helmets, and headgear. More specifically, aspects of the present invention provide, in various embodiments, a protective fluid-containing impact dissipating liner having a reinforcing fabric that enhances the strength and durability of the liner.

Numerous human activities, such as recreation and sports, public protection and armed services, expose the human body, especially the head, to shock and injury.

Head injuries can be the most traumatic type of bodily injury. Exposure of the human head to contact and injury, especially when there is movement, can be a persistent concern whether the movement was from a car or a bicycle. Many attempts have been made in the field of head protection to minimize damage to the skull, brain and brain stem from head impact.

Many prior art attempts to address these concerns have attempted to provide many “buffering” materials between the head and the surface of the impact, for example providing impact energy absorbing materials such as foam rubber and plastics. Various helmet designs were produced. Thus, in the state of helmet technology in the early 21st century, it is typical to provide a lot of foam cushioning in helmets without compromising the aesthetic appearance of the helmet. The resulting helmet has limited success in meeting head protection or esthetic goals.

Among other things, as the amount of cushioning material such as, for example, plastic foam increases, the outer skin becomes larger and the resulting helmet exposure increases. Specifically, more impact energy can be absorbed through the larger volume of cushioning material in the helmet, reducing the amount of impact energy transmitted to the head, and the larger volume can also be applied to contact points and contact points, such as the helmet wearer's neck, brainstem and torsional movement arms between the spinal cords. Accordingly, it is desirable to provide impact protection while minimizing torsional loads on the wearer.

Although a relatively minor result for some users, the higher the amount of cushioning material, the more unsightly the resulting helmet will typically appear to the average helmet wearer. Accordingly, there is a need in the art to ensure adequate head protection while providing a preferably aesthetically attractive helmet.

While many forms of activity can expose the head to impact loads, athletic completion or contact sports may be one of the more serious concerns about helmet design and head protection. It is well known that repeated head contact in contact sports such as football, hockey and soccer exposes athletes to degenerative brain damage, even if protected with some form of headgear. The incidence of chronic traumatic encephalopathy (CTE) in professional athletes, particularly former professional football and hockey players, is well documented. It is generally believed that repeated exposure of the head to shock loads, even when protected, can lead to deteriorating and life-changing effects on cognitive abilities and behavior. Efforts are ongoing to investigate the causes of CTE and to mitigate or prevent its occurrence. Accordingly, there is a need in the art to provide a more protected headgear to an athlete or the like.

In addition to head protection, many other physical, structural or decorative surfaces may be exposed to damage from damaging contact and/or impact loading. Among other activities, there is a continuing need for reinforcement of eg body armor or body padding for body protection during military activities, construction or personal protection. Protection of general walls, barriers and other surfaces from damage is also desirable.

U.S. Pat. No. 8,856,972 to Kirshon was the first to introduce the concept of liquid-filled, fluid-displaced liner technology into the art. This technology is marketed under the trademark ^{Fluid Displacement Liner™} technology or FDL ^™ technology by KIRSH Helmets of Schenectady, New York. While the invention disclosed in US Pat. No. 8,856,972 provides an effective means of dissipating impact loads, further improvements and advantages are provided by the present invention.

Aspects of the present invention provide protective impact dissipating liners, such as, for example, headgear, methods of minimizing the transfer of impact loads to surfaces such as the human body, and methods of making such impact dissipating liners.

Aspects of the present invention provide an improved impact dissipation liner that can be used whenever dissipation of an impact load is desired. Although aspects of the present invention may be particularly adapted to protect humans and animals, such as, for example, helmets, headgear, hazmat suits, body padding, knee guards, shoulder guards and shin guards, among others, aspects of the present invention may also be adapted to, for example, racing tracks It can be used wherever protection of impact-prone surfaces such as barriers, stadium walls and arena surfaces would benefit from impact-dissipating protection.

Aspects of the present invention include a flexible, fluid impermeable enclosure, a plurality of cavities extending through the enclosure, a fluid contained within the enclosure; and a method of making an impact dissipating liner and a method of making the impact dissipating liner, having a sheet of fabric positioned on the liner, such as to provide improved structural support, structural integrity, and/or durability to the liner.

One embodiment of the present invention provides a method of manufacturing an impact dissipating liner, the method comprising: providing a first mold adapted to receive a first curable fluid, the first mold comprising a surface, a plurality of pieces from the surface; having a protrusion and a plurality of recesses, each of the plurality of recesses being about one of the plurality of protrusions; introducing a first curable fluid into the first mold to at least partially fill the first mold, comprising at least partially filling each of the plurality of recesses; causing the first curable fluid to cure in each of the plurality of recesses and in at least a portion of the surface of the first mold, thereby creating an at least partially cured first liner portion; removing the at least partially cured first liner portion from the first mold, the at least partially cured first liner portion having a flexible sheet and a plurality of protrusions from the flexible sheet; providing a second mold adapted to receive a second curable fluid, the second mold having a surface and a plurality of protrusions from the surface; introducing the fabric sheet into at least a portion of the surface of the second mold, the fabric sheet having holes, each hole positioned and sized to receive one of the protrusions from the surface of the second mold; introducing a second curable fluid into the second mold to at least partially fill the second mold and at least partially cover the fabric sheet of the second mold; introducing an at least partially cured first liner portion into the second mold while the second curable fluid in the second mold is at least partially uncured, at least partially cured of the first liner portion the distal end of the plurality of protrusions contacting at least partially an uncured second curable fluid in the second mold; and allowing the second curable fluid to cure, forming a second flexible sheet attached to the distal end of the plurality of protrusions of the at least partially cured first liner portion, forming a fluid impermeable enclosure. ; and introducing the fluid into the fluid impermeable enclosure to provide an impact dissipating liner.

In one aspect, the fabric sheet may be a woven fabric, an unwoven fabric, or a knitted fabric. For example, the fabric sheet may be a knitted sheet including PET (polyethylene terephthalate), polyester, and aramid polymer.

In another aspect, a method may include sealing a peripheral edge of the at least partially cured first liner portion with a peripheral edge of a second flexible sheet of a second curable fluid. This sealing process may be performed while allowing the second curable fluid to cure.

In one aspect, the first curable fluid is substantially the same as the second curable fluid, and may be, for example, a liquid silicone rubber.

Another embodiment of the present invention is an impact dissipation liner, such as a liner for a helmet. The liner comprises: a flexible, fluid impermeable enclosure having an upper wall, an opposing lower wall and sidewalls extending between the upper and lower walls; a fabric sheet located on at least one of the upper wall and the lower wall; and a fluid contained in the enclosure. In one aspect, the liner includes a plurality of cavities extending between an upper wall and a lower wall, each of the plurality of cavities having a cavity sidewall extending from the upper wall to the lower wall.

In one aspect, the fabric sheet of the liner may be woven, non-woven, or knitted. For example, in one aspect, the fabric sheet may be a knitted combination comprising PET (polyethylene terephthalate), polyester, and aramid polymer.

In one aspect, the liner may be a helmet liner, and the flexible, fluid impermeable enclosure may be a central portion and a plurality of lobes extending from the central portion, the central portion and the plurality of lobes conforming to the shape of the inner surface of the helmet. is adjusted to

In one aspect, the fluid within the enclosure may be a liquid such as liquid silicone rubber, polydimethylsiloxane or polyol.

Another embodiment of the present invention provides a flexible, fluid impermeable enclosure having an upper wall, an opposing lower wall, and sidewalls extending between the upper and lower walls; and a fabric sheet positioned on at least one of the upper wall and the lower wall. The fabric sheet may be woven, non-woven or knitted. For example, the fabric sheet may be a knitted fabric made of PET (polyethylene terephthalate), polyester or aramid polymer. In one aspect, the liner comprises a plurality of cavities between the upper wall and the lower wall, each of the plurality of cavities having a cavity sidewall extending from the upper wall to the lower wall; fluid contained in the enclosure.

In one aspect, the liner may be a helmet liner, wherein the flexible, fluid impermeable enclosure comprises a central portion and a plurality of lobes extending from the central portion, the central portion and the plurality of lobes conforming to the shape of the inner surface of the helmet. is adjusted to The plurality of lobes may define cavities extending radially between adjacent lobes.

In one aspect, the fluid in the liner may be a liquid, such as liquid silicone rubber, polydimethylsiloxane or polyol.

Another embodiment of the present invention is a method of making an impact dissipating liner. The method includes: providing a first mold adapted to receive a first curable fluid, the first mold having a mold cavity having a lower surface, a plurality of protrusions from the lower surface and at least one recess in the lower surface have -; introducing the first curable fluid and the fabric sheet into at least one recess in the lower surface to at least partially fill the at least one recess in the lower surface with the first curable fluid; introducing a second curable fluid into the first mold to at least partially cover the lower surface with the second curable fluid; allowing the first curable fluid to cure in the at least one recess and allowing the second curable fluid to cure at the lower surface, thereby creating an at least partially cured first liner portion; coupling the first liner portion with the second liner portion to form a fluid impermeable enclosure; and introducing the fluid into the fluid impermeable enclosure to provide an impact dissipating liner. In one aspect, introducing the first curable fluid and the fabric sheet into the at least one recess sequentially first introduces the first curable fluid into the at least one recess and the second introduces the fabric sheet into the at least one recess. introducing into the at least one recess.

In one aspect, the fabric sheet may be a woven, non-woven or knitted fabric, such as polyethylene terephthalate (PET), polyester or aramid polymer.

In an aspect, introducing the fluid into the fluid impermeable enclosure may be effected by injecting the fluid into the fluid impermeable enclosure.

In one aspect, coupling the first liner portion with the second liner portion comprises providing a second mold adapted to receive a third curable fluid, the second mold having a surface and a plurality of cylindrical ribs at the surface. having set -; introducing a third curable fluid into the second mold to at least partially fill the first mold, comprising at least partially filling each of the plurality of recesses; causing the first curable fluid to cure in each of the plurality of recesses and in at least a portion of the surface of the first mold, thereby creating an at least partially cured second liner portion; and removing the at least partially cured second liner portion from the second mold, the at least partially cured second liner portion having a flexible sheet and a plurality of protrusions from the flexible sheet. by, manufacturing the second liner part.

A further aspect of the present invention is a flexible, fluid impermeable enclosure having an upper wall, an opposing lower wall, and sidewalls extending between the upper and lower walls; fluid contained in the enclosure; and a sheet of fabric positioned on at least one of the upper wall and the lower wall. In one aspect, the fabric sheet located on at least one of the upper wall and the lower wall comprises a plurality of fabric sheets located on one of the upper wall and the lower wall. In one aspect, the liner can include a plurality of cavities between the top wall and the bottom wall, each of the plurality of cavities having a cavity sidewall extending from the top wall to the bottom wall.

A still further embodiment of the present invention is a helmet having the impact dissipation helmet described herein. The helmet may include a helmet shell adapted to retain the impact dissipation helmet liner.

According to an aspect of the present invention, an impact dissipation liner and a method of making an impact dissipation liner are provided, the liner comprising, inter alia, a baseball catcher's helmet, a baseball batter's helmet, a softball catcher's helmet, a softball batter's helmet, a hockey helmet, Hockey Goalkeeper Helmet, Motorcycle Helmet, Motocross Helmet, Ski Helmet, Snowboard Helmet, Skateboard Helmet, Lacrosse Helmet, Bicycle Helmet, Jockey Helmet, Official Helmet, Medical Protective Helmet, Rock or Ice Climbing Helmet, Mountaineering Helmet, Football It can be used in helmets, construction helmets and military helmets.

These and other aspects, features and advantages of the present invention will become apparent from the following detailed description of various aspects of the invention considered in conjunction with the accompanying drawings.

The subject matter regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of this specification. The foregoing and other objects, features and advantages of the present invention will be readily understood from the following detailed description of aspects of the invention taken in conjunction with the accompanying drawings herein.
1 is a perspective view of an impact dissipation liner in accordance with an aspect of the present invention.
FIG. 2 is a cross-sectional view of the liner shown in FIG. 1 taken along section line 2-2 of FIG. 1 ;
Fig. 3 is a cross-sectional view of the liner shown in Fig. 1 taken along section line 3-3 of Fig. 1;
FIG. 4 is a detailed view of the liner shown in FIG. 3 , identified as detail 4 in FIG. 3 ;
5 is a perspective view of a mold for making a portion of the impact dissipating liner shown in FIG. 1 in accordance with an aspect of the present invention;
6 is a perspective view of an at least partially cured portion of an impact dissipating liner produced from the mold shown in FIG. 5 in accordance with an aspect of the present invention;
7 is a perspective view of a mold for manufacturing another portion of the impact dissipating liner shown in FIG. 1 in accordance with an aspect of the present invention;
8 is a top view of the mold shown in FIG. 7 with a curable fluid.
9 is a cross-sectional view of the mold and curable fluid shown in FIG. 8 taken along section line 9-9 of FIG. 8 ;
10 is a cross-sectional view of the liner portion shown in FIG. 6 and the mold shown in FIGS. 7-9 prior to connection in accordance with an aspect of the present invention;
11 is a cross-sectional view of the liner portion and mold shown in FIG. 10 after connection in accordance with another aspect of the present invention.
12 is a top view of another mold with a curable fluid for making a portion of a liner in accordance with another aspect of the present invention.
13 is a perspective view of the moldable and curable fluid shown in FIG. 12 ;
14 is a perspective view of a portion of a liner made from the mold shown in FIG. 13 ;
FIG. 15 is a detailed perspective view of a portion of the portion of the liner shown in FIG. 14 ;
16 is a top view of another mold with a curable fluid for making another portion of a liner in accordance with another aspect of the present invention.
Fig. 17 is a detailed perspective view of the mold shown in Fig. 16;
18 is a plan view of the moldable and curable fluid shown in FIGS. 16 and 17 having a fabric in accordance with an aspect of the present invention.
19 is a perspective view of the moldable and curable fluid shown in FIG. 18 having a fabric in accordance with an aspect of the present invention.
20, 21 and 22 are perspective views of the mold, curable fluid and fabric shown in FIG. 19 while the curable fluid is introduced in accordance with aspects of the present invention.
23 is an impact dissipating liner produced by combining the liner portion shown in FIGS. 14 and 15 with a liner portion created by the mold, curable fluid and fabric shown in FIGS. 16-22 in accordance with an aspect of the present invention; is a perspective view of
FIG. 24 is another impact generated by combining the liner portion shown in FIGS. 14 and 15 with a liner portion created by the mold, curable fluid and fabric shown in FIGS. 16-22 in accordance with an aspect of the present invention. A perspective view of the dissipation liner.
Fig. 25 is a perspective view of a portion of the liner shown in Fig. 24;
FIG. 26 is a detailed perspective view of a portion of the liner shown in FIG. 25 ;
Fig. 27 is a detailed top perspective view of a portion of the liner shown in Fig. 25;
28 is a perspective view in the form of a human head with a helmet, partially shown in cross-section, comprising a fluid filled liner having regions with reinforcing elements in accordance with another aspect of the present invention;
29 is a perspective view in the form of a human head showing the fluid filled liner shown in FIG. 28 with the helmet having the helmet shell removed to disclose an aspect of the invention similar to that of FIG.
30 is a perspective view of the fluid filled liner shown in FIGS. 28 and 29;
FIG. 31 is a top view of the fluid filled liner shown in FIG. 30 ;
FIG. 32 is a right elevational view of the fluid filled liner shown in FIG. 31 , and the left elevational view is a mirror image thereof.
FIG. 33 is a cross-sectional view of a portion of the fluid filled liner shown in FIG. 30 , as viewed through section line 33-33 shown in FIG. 31 ;
34 is a top perspective view of a mold that may be used to manufacture a portion of a fluid filled liner in accordance with an aspect of the present invention.
FIG. 35 is a detailed plan view of the mold shown in FIG. 34, identified by detail 35 in FIG. 34;
36 is a top view of a reinforcing element that may be used in accordance with aspects of the present invention.
FIG. 37 is a detailed plan view of one reinforcing element shown in FIG. 36 ;
38 is a top perspective view of the mold shown in FIG. 34 having a cavity at least partially filled with a curable fluid in accordance with an aspect of the present invention.
FIG. 39 is a top perspective view of the mold shown in FIG. 38 with two of the reinforcing elements shown in FIG. 36 and a cavity at least partially filled with a curable fluid in accordance with an aspect of the present invention;
40 is a top perspective view of a portion of a liner having a reinforcing element after curing and removal from the mold of the curable fluid shown in FIG. 39 in accordance with an aspect of the present invention;
41 is a perspective view of a portion of the liner shown in FIG. 40 showing details of a reinforcement region having a reinforcement element in accordance with an aspect of the present invention;
FIG. 42 is a top perspective view of a fluid filled liner made from the liner portion shown in FIG. 40 after mating with a second portion and filled with fluid in accordance with an aspect of the present invention;
43 is a bottom view of a helmet having the fluid filled liner shown in FIG. 42 in accordance with an aspect of the present invention.

1 is a perspective view of an impact dissipation liner 10 in accordance with an aspect of the present invention. 1 , in one aspect, the liner 10 comprises a top sheet or wall 12 , a bottom sheet or wall 14 , and a plurality of extending between the top sheet 12 and the bottom sheet 14 . A flexible, fluid impermeable enclosure having a hollow protrusion 16 and sidewalls 18 around the perimeter of the top and bottom sheets 12 and 14 and extending between the top and bottom sheets 12 and 14. (11) may be included. The hollow protrusion 16 may define a hollow cavity 17 , such as an open or closed hollow cavity. Cavities 17 may each include cavity sidewalls extending from top sheet 12 to bottom sheet 14 .

In accordance with aspects of the present invention, at least one of the sheets 12 and 14 comprises one or more fabric layers 20, such as a reinforcing fabric capable of providing enhanced strength and durability to a liner in accordance with aspects of the present invention; The liner 10 may provide improved protection, such as improved impact resistance or dissipation, to the surface adjacent the liner 10 . A portion of fabric 20 is shown in the cut-away portion of topsheet 12 in FIG. 1 .

FIG. 2 is a cross-sectional view of the liner 10 shown in FIG. 1 taken along section line 2-2 of FIG. 1 . FIG. 3 is a cross-sectional view of the liner 10 shown in FIG. 1 taken along section line 3-3 of FIG. 1 . FIG. 4 is a detailed view of the liner 10 shown in FIG. 3 , identified as detail 4 in FIG. 3 .

In accordance with aspects of the present invention, seats 12 and 14, projections 16 and sidewalls 18 define a sealed, substantially fluid-tight cavity 22, wherein fluid 24 is configured to provide an impact dissipating liner. introduced into the cavity 22 . Fluid 24 may be introduced into cavity 22 by conventional means such as, for example, injection via syringe 26 , as shown in FIG. 1 .

In accordance with aspects of the present invention, fluid 24 within interior cavity 22 and elasticity of sheets 12 and 14, projections 16 and sidewalls 18, for example, from top sheet 12 to bottom sheet 14 It provides a unique energy dissipation function that minimizes or reduces the load transferred to the This energy or impact dissipation property of the liner 10 provides a hollow, possibly gas-filled (eg, air-filled) cavity 17 in the protrusion 16 to dissipate load and/or energy transfer to the surface. It can provide an effective device for It is understood that one or more layers of fabric 20 in sheet 12 and/or 14 enhance durability and strength, if not the impact-dissipating properties of liner 10 .

5 is a perspective view of a mold 30 for manufacturing a portion of the impact dissipating liner 10 shown in FIGS. 1-4 in accordance with an aspect of the present invention. 5 , according to an aspect of the present invention, a curable or hardenable fluid 32 , such as a liquid silicone rubber (LSR) is introduced into a mold 30 and then cured The ringable fluid 32 is allowed to cure, ie to solidify or harden to form part of the impact dissipation liner 10 . As will be described below, in accordance with aspects of the present invention, a portion of the impact dissipation liner formed in the mold 30 is then combined with another portion of the impact dissipation liner to be a substantially complete liner that can be filled with a fluid, such as a liquid. (10) can be prepared.

According to aspects of the present invention, the curable or hardenable fluid 32 can include any liquid or fluid that can be introduced into the mold 30 or any mold disclosed herein, and thereafter at an appropriate time and It has been cured or at least partially hardened through processing so that it is subsequently moved, manipulated and/or as a single integral component as disclosed herein while maintaining a relatively rigid structure, such as a substantially molded shape. It forms a structure that can be otherwise processed. For example, the curable fluid 32 and any liner or liner enclosure disclosed herein may include a fluid polymer that is hardened upon appropriate processing, eg, by crosslinking polymer chains. Curing may be effected by time, temperature, chemical additives and/or radiation, such as electron beam or ultraviolet radiation. The curable fluid 32 and any liner or liner portion formed from the curable fluid 32 disclosed herein may be made of an elastomeric material, such as natural or synthetic rubber, foam, thermoplastic elastomer, polyurethane, among others. elastomers, silicone elastomers, polyvinyl chloride (PVC) elastomers, olefin elastomers, polyamide elastomers or gelatin elastomers. In one aspect, the curable fluid 32 may be silicone, such as liquid silicone rubber (LSR) or the like.

In one aspect, the curable or hardenable fluid 32 and any curable or hardenable fluid disclosed herein may comprise a “medical grade” LSR known in the art. In one aspect, the enclosure 11 of the liner 10 may comprise liquid silicone rubber sold by the trademark True Skin® or CHT USA (formerly Quantum Silicones (QSi)) or equivalent; However, the enclosure 11 may include any liquid silicone rubber (LSR).

In FIG. 5 , a curable or hardenable fluid 32 is typically shown flowing from a container 34 to a mold 30 ; However, in accordance with aspects of the present invention, fluid 32 may be introduced into mold 30 by any conventional means. For example, fluid 32 may be introduced into mold 30 via injection, gravity feed, one or more nozzles and/or one or more valves, among other methods. In one aspect, fluid 32 may be introduced flowing from one or more vessels 34 .

As shown in FIG. 5 , mold 30 may include a surface 36 , eg, uniformly distributed around a plurality of recesses 38 , eg, surface 36 . and a “plurality” of recesses distributed in such a way that a curable fluid 32 flows therethrough and substantially fills each recess 38 with the curable fluid 32 . Although nine representative recesses 38 are shown in FIG. 5 , aspects of the present invention may have from a minimum of one recess to tens, hundreds or even thousands of recesses 38, depending on the application of the aspects of the present invention. have.

Surface 36 and recess 38 may typically be formed in block, panel or plate 40 . The mold 30 may include, for example, a rim or peripheral barrier 42 surrounding the perimeter of the plate 40 , the rim 42 being the curable fluid 32 introduced into the mold 30 . ) can function to maintain In one aspect, the mold 30 may be referred to as "Mold A" in the manufacturing process, two molds, A mold/B mold. Additional aspects and details of mold 30 may be found and described with respect to FIGS. 1-8 of co-pending US patent application 15/833,747, the disclosure of which is incorporated herein by reference in its entirety.

After allowing the curable fluid 32 to cure (or harden), for example, for at least about 1 hour to at least about 6 hours, in accordance with one aspect of the present invention, the cured fluid 32 is applied with an impact dissipating liner. form part of

6 is a perspective view of an at least partially cured portion 46 of an impact dissipation liner produced from the mold 30 shown in FIG. 5 in accordance with an aspect of the present invention. In one aspect of the present invention, portion 46 includes cured fluid 32 of the impact dissipating liner removed from mold 30 , such as a “first cured fluid”. As shown in FIG. 6 , a portion 46 is formed from a flexible sheet 48 defined by a cured fluid and a cured curable fluid in a plurality of recesses 38 of the mold 30 . a sheet 48 including a plurality of protrusions 49 , such as a “first flexible sheet” (see FIG. 5 ). The protrusion 49 and any protrusion disclosed herein may include the shape and dimensions of the recess 38 disclosed herein, eg, a right circular or non-circular cylindrical protrusion. Also, as shown in FIG. 6 , portion 46 may include one or more peripheral walls or barriers 47 (shown in phantom lines). Wall 47 may be formed from a cured fluid 32 that typically solidifies in a peripheral slot (not shown) of mold 30 .

According to aspects of the invention, the sheet 48 of portion 46 may have a thickness in the range of about 0.5 millimeters (mm) to about 30 mm, although the thickness of the sheet 48 will typically range from about 1 mm to about 5 mm. can The thickness of the wall 47 may be similar to the thickness of the sheet 48 .

In accordance with aspects of the present invention, portion 46 shown in FIG. 6 may include a first portion of at least two portions of a cured fluid that may be used to manufacture an impact dissipating liner according to aspects of the present invention. . In one aspect, the at least partially cured portion 46 may be referred to as “Part A” in the two molds, Part A/Part B, manufacturing process. 7-11 illustrate the manufacture of a second portion or “Part B” of the impact dissipating liner that may be combined with the portion 46 shown in FIG. 6 .

7 is a perspective view of a mold 50 for manufacturing another or a second portion of the impact dissipating liner shown in FIG. 1 in accordance with an aspect of the present invention. As shown in FIG. 7 , in this aspect, the mold 50 is adapted to receive a curable fluid 52 , such as a “second curable fluid”. The mold 50 may include a surface 54 formed on a block, panel or plate 56 and a protrusion 60 from the surface 54 . The mold 50 may include, for example, a rim or peripheral barrier 58 surrounding the perimeter of the plate 56 , the rim 58 holding the curable fluid 52 introduced into the mold 50 . can function to

As shown in FIG. 7 , the mold 50 may include a plurality of protrusions 60 , such as a plurality of cylindrical protrusions, such as circular cylindrical or rectangular cylindrical protrusions. In one aspect, the mold 50 may be referred to as a "B mold" in the manufacturing process, two molds, A mold/B mold.

The mold 30 shown in FIG. 5 and the mold 50 shown in FIG. 7 and any molds disclosed herein may be provided from any suitable material, such as wood, plastic or metal. For example, in one aspect, molds 30 and 50 may be made of wood, such as hardwood. In other embodiments, molds 30 and 50 may be made of conventional plastic molded from, for example, polyethylene. In another aspect, molds 30 and 50 may be formed or machined from a metal, such as steel, stainless steel, tool steel, or aluminum.

According to one aspect of the present invention, a curable fluid 52 , such as a “second curable fluid”, may be introduced to the surface 54 having the protrusion 60 of the mold 50 , and The surface 54 may be at least partially covered with the untreated fluid 52 . Curable fluid 52 is shown flowing representatively from container 53 to mold 30 ; However, in accordance with aspects of the present invention, fluid 52 may be introduced into mold 50 by any conventional means, such as through one or more nozzles (not shown).

FIG. 8 is a top view of the mold 50 shown in FIG. 7 with the curable fluid 52 . 9 is a cross-sectional view of the mold 50 and the curable fluid 52 shown in FIG. 8 taken along section line 9-9 in FIG. 8 .

As shown in FIG. 9 , before, after, or during introducing the curable fluid 52 into the mold 50 , at least some fabric 62 may typically be introduced into the mold 50 . If curable fluid 52 is present, fabric 62 may contact and/or be immersed in curable fluid 52 . According to aspects of the present invention, fabric 62 may include one or more pieces of fabric, may contact curable fluid 52 , and/or be at least partially on surface 54 of mold 50 . can be contacted with Two or more pieces of fabric 62 are placed one on top of another piece of fabric or side by side, for example, with or without overlapping pieces of fabric. In one aspect, the fabric 62 may be shaped to cover or connect substantially the entire exposed surface 54 of the mold 50 ; However, in some aspects, the fabric 62 may not cover the entire surface, eg, due to manufacturing tolerances and/or to facilitate assembly of the fabric 62 to the mold 50 .

As shown in FIG. 9 , fabric 62 may include more than one, but will typically include a plurality of perforations or holes 64 positioned and sized to connect to protrusions 60 of mold 50 . can The perforations 64 may be circular when the protrusions 60 are circular cylindrical as shown in FIGS. 8 and 9 , but the perforations 64 in the fabric 62 can be, for example, when the protrusions 60 are not circular cylindrical. It may be non-circular. Accordingly, the perforations 64 may be oval, triangular, square, rectangular, pentagonal, hexagonal, or any other polygonal shape.

According to aspects of the present invention, fabric 62 may comprise any woven, non-woven, knitted or non-knitted fabric or sheet material. In one aspect of the present invention, structure 62 may be referred to as a “fabric,” although any form of thin material, cloth or textile may be used for fabric 62 and disclosed herein. It is contemplated that it may provide an enhancement to the liner. In one aspect, fabric 62 may be any form of thin material made, such as by weaving, felting and/or knitting, for example, of natural and/or synthetic fibers and/or filaments. In one aspect, the fabric 62 may be flexible, ie, it may be easily bent or deformed.

According to aspects of the present invention, the fabric 62 may have a thickness in the range of about 0.001 inches (in.) to about 0.25 inches, but is typically in the range of about 0.005 inches to about 0.05 inches, such as about 0.0085 inches. may have a thickness.

In one aspect, fabric 62 may be a material made from natural materials, plastics, elastomers, or metals. For example, fabric 62 may be made of cellulosic fibers, such as silk fibers, wood fibers, rayon fibers, and/or carbon fibers. In other aspects, fabric 62 may be made of a metal sheet or metal fiber, such as a thin aluminum, steel or stainless steel sheet or woven metal filament. In one aspect, fabric 62 is made of one or more elastomeric or rubber materials, such as the following elastomers: natural polymers such as polyisoprene rubber or neoprene, thermoplastic elastomers, thermoplastic rubber and polyvinyl chloride, or ethylene propylene diene monomer (EPDM). It may be made of one or more of thin sheets or woven filaments, such as synthetic polymers such as rubber.

In one aspect, fabric 62 may be made of fiberglass, such as chopped strand fiberglass and/or woven fiberglass. In one aspect, the fabric 62 may be a woven fiberglass tissue or a woven fiberglass veil known in the art.

In one aspect, fabric 62 may be made of carbon fibers, such as chopped strands and/or woven carbon fibers such as micro and/or nano fibers.

In one aspect, fabric 62 may be made of a thin plastic sheet or film, or plastic fibers or filaments. For example, fabric 62 may be made of the following plastics: polyamide (PA), such as nylon, among other plastics; aramid polymers such as Nomex® or Kevlar® polymers; all polyethylene (PE), high density polyethylene (HDPE) and low density polyethylene (LDPE); polyethylene terephthalate (PET) such as Dacron® polymer; polypropylene (PP); polyester (PE); polytetrafluoroethylene (PTFE); polystyrene (PS); acrylonitrile butadiene styrene (ABS); polycarbonate (PC); or polyvinyl chloride (PVC), a thin sheet of one or more of, or a thin fabric. For example, fabric 62 may include a combination of polyethylene terephthalate (PET) (eg, Dacron® PET), polyester, and an aramid polymer (eg, Nomex® aramid polymer).

In one aspect, fabric 62 may be composed of fibers or filaments having a thickness, ie, denier or denier/filament. For example, in one aspect the fabric 62 may have a denier/filament of about 40/24.

In one aspect, fabric 62 may be comprised of fibers or filaments having a turn or twist per inch (TPI). For example, in one aspect the fabric 62 may have a twist per inch of from about 0.1 TPI to about 5.0 TPI, eg, about 0.5 TPI in the “Z twist” direction, or “0.5Z”.

In one aspect, fabric 62 may be treated, such as scoured, to remove undesirable substances such as dust, oil and/or grease. In one aspect, fabric 62 may be heat set to minimize shrinkage.

In one aspect, fabric 62 may be a fabric provided by Mohawk Fabrics Company, Inc. of Amsterdam, New York. For example, in one aspect, fabric 62 may be made of a material sold under model number “SP 403” or equivalent.

10 is a cross-sectional view of the liner portion 46 shown in FIG. 6 and the mold 50 shown in FIGS. 7-9 prior to connection in accordance with an aspect of the present invention. 11 is a cross-sectional view of the liner portion 46 and mold 50 shown in FIG. 10 after connection in accordance with another aspect of the present invention.

According to one aspect of the present invention, after introducing the fabric 62 into the mold 50 , after introducing the curable fluid 52 , and at least partial curing or hardening of the curable fluid 52 . Prior to curing, for example, as shown in FIG. 6 , a portion 46 of the impact dissipation liner may have an uncured or at least partially cured fluid in the mold 50 as shown in FIGS. 10 and 11 . 52 ) to couple portion 46 with uncured, curable fluid 52 . A representative representation of the fabric 62 prior to being introduced into the mold 50 is shown in phantom line in FIG. 10 for reference.

As indicated by arrow 66 in FIG. 10 , in one aspect, portion 46 may be coupled with uncured portion 52 , eg, uncured portion 52 may include protrusion 49 . may contact the lower distal end or distal end 68 of the protrusion 49 to at least partially contact or insert the distal end 68 of the protrusion 49 into the fluid 52 . In one aspect, the flexible sheet 46 of the first cured fluid and the plurality of protrusions 49 may be introduced into the second curable fluid 52 and the fabric 62, wherein the plurality of protrusions The distal end 68 of 49 is in contact with the fabric 62 and the second curable fluid 52 .

Once the distal end 68 of the protrusion 49 is in contact with the fabric 62 and/or inserted into the fluid 52 , the fluid 52 , such as a “second curable fluid,” is cured or cured. allowed to form a second portion of a second flexible sheet 52 , ie, an impact dissipation liner, wherein the flexible sheet 52 is attached to the distal end 68 of the plurality of protrusions 49 . . The assembled and cured portions 46 and 52 are illustrated by the assembled liner 10 shown in FIG. 1 .

Aspects of the invention shown and described in connection with Figures 1-11 include general features of various aspects of the invention. Although the shape of the molds 30 and 50 and the resulting liner portion is shown as a rectangular shape in FIGS. 1-11 , this rectangular shape is non-limiting and is used to facilitate the disclosure of aspects of the present invention. It is contemplated that aspects of the present invention are not limited to rectangular shapes, but may be implemented and provided in any convenient shape consistent with a desired application, such as, for example, desired protection of surfaces from impact loads, among others. The following disclosure and drawings illustrate several more specific shapes of again non-limiting embodiments of the general features and aspects disclosed in FIGS. 1-11 .

12 is a top view of another mold 70 having a curable fluid 72 for making portions of a liner in accordance with another aspect of the present invention. Although aspects of the present invention may be used to protect structures or any suitable surface of a human or animal, in the aspect of the present invention shown in FIG. 12 , the mold 70 is a liner for a headgear, such as a motorcycle helmet liner. Shaped and sized to provide a helmet liner such as 13 is a perspective view of the mold 70 and the curable fluid 72 shown in FIG. 12 .

12 and 13 , in accordance with aspects of the present invention, a curable fluid 72 or a “first curable fluid” such as liquid silicone rubber (LSR) is introduced into a mold 70 and , the curable fluid 72 is then allowed to cure, ie, solidify or harden to form part of the impact dissipating liner. As discussed herein, in accordance with aspects of the present invention, a portion of the impact dissipation liner formed in the mold 70 may then be combined with another portion of the impact dissipation liner to form a substantially complete liner, which then comprises a fluid, For example, it may be filled with a liquid.

12 and 13 , mold 70 may include a surface 74 , which is distributed, eg, uniformly, with respect to a plurality of protrusions 76 and surface 74 respectively. and recesses 78 surrounding the evenly distributed protrusions 76 into which a curable fluid 72 flows and substantially fills each recess 78 with the curable fluid 72 . . 12 and 13 , a recess 78 is located below the fluid 72 and is identified by an imaginary line. As shown, the protrusions 76 may be cylindrical, eg, circular cylindrical, and the recesses 78 may be circular, although other geometric or non-circular shaped protrusions and recesses may be used. While the number of protrusions 76 and recesses 78 shown in Figures 12 and 13 is representative of aspects of the present invention, embodiments of the present invention may include, for example, a minimum of five protrusions, depending on the size and application of the aspects of the present invention. From 76 and recess 78 it can have tens, hundreds or even thousands of projections 76 and recesses 78 .

Surface 74 and protrusions 76 and recesses 78 may typically be formed from blocks, panels, or plates 80 . The mold 70 may include, for example, a rim or peripheral barrier 82 surrounding the perimeter of the plate 80 , the rim 82 holding the curable fluid 72 introduced into the mold 70 . can function to In one aspect, mold 70 has one or more peripheral recesses or slots 83 (fluid 72 in FIGS. 12 and 13 ) adapted to receive curable fluid 72 in a manner similar to recess 78 . below), and in other aspects, the recess or slot 83 may be omitted. In one aspect, the mold 70 may be referred to as “Mold A” in the manufacturing process, two molds, A mold/B mold. Additional aspects and details of mold 80 may be found and described with respect to FIGS. 1-8 of co-pending US patent application 15/833,747, the disclosure of which is incorporated herein by reference in its entirety.

After allowing the curable fluid 72 to cure (or harden), eg, for at least about 1 hour to at least about 6 hours, in accordance with one aspect of the present invention, the cured fluid 72 is applied to an impact dissipating liner. may include a part of

14 is a perspective view of a portion 84 of a liner made from the mold 70 shown in FIGS. 12 and 13 in accordance with an aspect of the present invention. FIG. 15 is a detailed perspective view of a portion of portion 84 of the liner shown in FIG. 14 . In one aspect of the invention, the portion 84 comprising the cured fluid 72 of the impact dissipation liner, eg, the “first cured fluid,” is removed from the mold 70 . 14 and 15 , portion 84 includes a plurality of recesses 78 in a sheet 86 , such as a “first flexible sheet” and mold 70 , containing the cured fluid. a plurality of protrusions 88 from the flexible sheet 86 defined by the curable fluid cured in . The protrusion 88 and any of the protrusions disclosed herein may include the shape and dimensions of the recess 78 disclosed herein, such as, for example, right-angled circular or non-circular cylindrical protrusions. 14 and 15 , portion 84 may include one or more peripheral walls or barriers 90 . Wall 90 may be formed from a cured fluid 72 that typically solidifies in peripheral slot 83 of mold 70 . In one aspect, part 84 may be referred to as a two-part, Part A/Part B, “Part A” or “Part A” manufacturing process.

Although not shown in FIGS. 12-15 , in one aspect, one or more fabric sheets, such as one or more fabric reinforced sheets, may be applied to the portion 84 , such as as shown and described below in connection with FIGS. 16-22 . may be introduced into the seat 86 . According to this aspect, the fabric sheet in the sheet 86 of the portion 84 may enhance the properties of the liner with the fabric sheet 120 (see below) to provide two reinforcing sheets. In other aspects, the one or more sheets of fabric introduced into portion 86 may be the only sheets of liner, and the second layer or sheet 120 (see below) may be omitted.

16 is a top view of another mold 100 having a curable fluid 102 for making another portion of a liner in accordance with another aspect of the present invention. 17 is a detailed perspective view of a portion of the mold 100 shown in FIG. 16 . 16 and 17 , in this aspect, the mold 100 is adapted to receive a curable fluid 102 , such as a “second curable fluid.” The mold 100 may include a surface 104 formed on a block, panel or plate 106 , such as a rim or peripheral barrier 108 surrounding the perimeter of the plate 106 , The rim 108 may function to retain the curable fluid 102 introduced into the mold 100 .

As shown in FIGS. 16 and 17 , the mold 100 may include a plurality of protrusions 110 , such as a plurality of cylindrical protrusions, such as circular cylindrical or rectangular cylindrical protrusions. In one aspect, the mold 100 may be referred to as "Mold B" in the manufacturing process, two molds, A mold/B mold.

18 is a top view of the mold 100 and the curable fluid 102 shown in FIGS. 16 and 17 having a fabric 120 in accordance with an aspect of the present invention. 19 is a perspective view of the mold 100 and the curable fluid 102 shown in FIG. 18 with the fabric 120 immersed in or contacting the curable fluid 102 in accordance with an aspect of the present invention. Fabric 120 may have and are similar to all properties of fabric 62 disclosed herein. For example, fabric 120 may typically include one or more pieces of fabric, may contact curable fluid 52 , and/or may at least partially contact surface 104 of mold 100 . The fabric 120 may be shaped to substantially cover or connect the entire exposed surface 104 of the mold 100 . However, in some aspects, the fabric 120 may not cover the entire surface 104 , such as due to manufacturing tolerances and/or to facilitate assembly of the fabric 62 into the mold 100 .

Also shown in FIG. 18 , in one aspect, the fabric 120 may be colored or tinted, which would be an effective means of providing an indication of the presence of the fabric 120 within, for example, an impact dissipating liner, among others. It can have a unique color. For example, fabric 120 may have a unique color, such as the bright orange shown in FIG. 18 , although other colors or color combinations may be used for fabric 120 , such as red, green, blue, indigo or purple. The colored fabric 120 may be placed within another transparent, translucent, colorless, or faintly colored liner material, such as cured liquid silicone rubber (LSR). In one aspect, the color of the fabric 120 may be reflective or visible with low or no lighting such that when the fabric containing liner is exposed, the liner may provide an alert or identification to others. In one aspect, fabric 120 may include a pattern of one or more colors, such as an image, a logo, one or more words or trademarks, and the like.

18 and 19 , the fabric 120 may include one or more, but typically a plurality of perforations or holes 122 positioned and sized to connect with the protrusions 110 of the mold 100 . have. The perforations 122 may be circular when the protrusions 110 are circular cylindrical as shown in FIGS. 18 and 19 , but the perforations 122 in the fabric 120 may be, for example, when the protrusions 110 are not circular cylindrical. It may be non-circular. Accordingly, the perforations 122 may be oval, triangular, square, rectangular, pentagonal, hexagonal, or any other polygonal shape.

According to aspects of the present invention, fabric 120 may include any woven, nonwoven, knitted or non-knitted fabric or sheet material disclosed herein, and may be made of one or more of any of the materials, wherein It may have one or more of the disclosed properties and dimensions. For example, in one aspect, the fabric 120 may be provided by Mohawk Fabric Company, Inc., for example, the fabric 120 may be a material sold under model number “SP 403” or equivalent thereto as disclosed herein. can be made of

Again, as in fabric 62 disclosed herein, a structure referred to as fabric 120 may be referred to as a “fabric,” although any form of thin material, cloth or textile may be used in fabric 120 and , which is contemplated may provide an enhancement to the liners disclosed herein. In one aspect, fabric 120 may be any form of thin material made, for example, by weaving, felting and/or knitting, for example, of natural and/or synthetic fibers and/or filaments. In one aspect, the fabric 120 may be flexible, ie, it may be easily bent or deformed.

20, 21 and 22 are perspective views of the mold 100, the curable fluid 102 and the fabric 120 shown in FIGS. 18 and 19 while the curable fluid 102 is introduced in accordance with aspects of the present invention. to be. In one aspect of the present invention, curable fluid 102 may be introduced into mold 100 by any conventional means, such as over fabric 120 . However, as shown in the aspects of the present invention shown in FIGS. 20 , 21 and 22 , the curable fluid 102 may be introduced via one or more injection nozzles 130 . For example, the nozzle 130 may be in fluid communication with a curable fluid supply (not shown) and may, for example, be introduced into the mold 100 manually or automatically under pressure. For example, in one aspect, the nozzle 130 may be controlled by an automated controller, such as a controller having a program running on a digital device, such as a programmable logic controller (PLC) or a computer, where one or more nozzles ( The position of 130 and the flow of the curable fluid 102 are controlled and monitored based on, for example, user input and user feedback.

According to one aspect of the present invention, after introduction of fabric 120 and uncured fluid 102 into mold 100 and at least partially curing or hardening uncured fluid 102 . Prior to this, a portion 84 of the impact dissipation liner may be introduced into the uncured or at least partially cured fluid 102 in the mold 100 as shown, for example, in FIGS. 14 and 15 , such as in FIG. Portion 84 may be coupled with fluid 102 in the manner shown at 10 and 11 .

In one aspect, the portion 84 shown in FIGS. 14 and 15 may be coupled with the uncured portion 102 , eg, the uncured portion 102 may be a protrusion 88 of the portion 84 . may contact or insert the distal end of the protrusion 88 into or at least partially contacting the fluid 102 . Once the distal end of the protrusion 88 contacts the fabric 120 and/or is inserted into the fluid 102 , the fluid 102 , such as a “second curable fluid,” is cured or allowed to cure. , forming a second flexible sheet 102 , ie, a second portion 102 of the impact dissipating liner, wherein the flexible sheet formed from the cured fluid 102 comprises a plurality of protrusions 88 of the portion 84 . ) is attached to the distal end of the Assembled liner 140 shown in FIG. 23 shows one example of assembled and cured portions 84 and 102 .

23 shows the liner portion 84 shown in FIGS. 14 and 15 by the mold 100, the curable fluid 102 and the fabric 120 shown in FIGS. 16-22 in accordance with an aspect of the present invention. A perspective view of an impact dissipating liner 140 produced by engaging a portion of the resulting liner. The impact dissipation liner 140 includes a flexible, fluid impermeable enclosure 141 having a top wall 143 , a bottom wall 145 , and a sidewall 149 between the top and bottom walls 143 and 145 . include In accordance with aspects of the present invention, the liner 140 includes a plurality of cavities 147 extending between an upper wall 143 and a lower wall 145 , each of the plurality of cavities 147 from an upper wall to a lower wall. has a cavity sidewall extending into A portion of the liner 140 is shown cut away in FIG. 23 to illustrate one relative position of the fabric 120 in the liner 140 . In one aspect of the present invention, the liner 140 comprises at least two sheets of fabric 120 , such as one or more sheets 120 inserted in a cured fluid 102 and a cured portion of the liner portion 84 . It may include one or more sheets inserted into the sheet 86 .

In accordance with aspects of the present invention, as disclosed herein, the liner 140 includes an interior substantially fluid tight cavity 142 , wherein the fluid 144 is introduced into the cavity 142 to provide an impact dissipating liner. do. Fluid 144 may be introduced into cavity 142 by conventional means, such as via syringe 26 , as shown in FIG. 1 .

Fluid 144 may be any liquid or gas that provides the desired shock dissipation properties. For example, fluid 144 may be substantially water; In another aspect, the fluid may be an oil, such as a naturally occurring oil or a synthetic oil. In one aspect, the fluid may comprise a diol, such as ethylene glycol and/or propylene glycol. In one aspect, the fluid may be saline or its equivalent. In one aspect, fluid 144 may be a polyol, such as a polyether polyol. In one aspect, fluid 144 may be a polyether polyol provided by EverChem Specialty Chemicals of Media, Pennsylvania, such as a polyether polyol provided by Everchem under the trade designation PPG-1000 Polyol. have.

In other embodiments, fluid 144 may be a polydimethylsiloxane fluid (also known as a “silicone fluid”), such as polydimethylsiloxane fluid sold as QM diluent by CHT USA or equivalent; However, fluid 144 may include any polydimethylsiloxane fluid. As is known in the art, polydimethylsiloxane includes a group of polymeric organosilicon compounds commonly referred to as “silicones”. Polydimethylsiloxane may be abbreviated as “PDMS” and has the formula [(CH ₃ ) ₂ SiO] _n . However, in other aspects, fluid 144 may be any fluid comprising water, such as distilled water.

24 shows the liner portion 84 shown in FIGS. 14 and 15 by the mold 100, the curable fluid 102 and the fabric 120 shown in FIGS. 16-22 in accordance with aspects of the present invention. A perspective view of another impact dissipating liner 150 created by engaging a portion of the resulting liner and having a fluid therein. Fig. 25 is a perspective view of the liner shown in Fig. 24; FIG. 26 is a detailed perspective view of the liner shown in FIG. 25 ; FIG. 27 is a detailed plan view of the liner shown in FIG. 25 ; The impact dissipation liner 150 includes a flexible, fluid impermeable enclosure 151 having a top wall 153 , a bottom wall 155 , and a sidewall 159 between the top wall 153 and the bottom wall 155 . do. In accordance with aspects of the present invention, the liner 150 includes a plurality of cavities 157 extending between an upper wall 153 and a lower wall 155 , each of the plurality of cavities 157 from an upper wall to a lower wall. has a cavity sidewall extending into

As most clearly shown in FIG. 27 , in accordance with one aspect of the present invention, fabric 120 is lined with fabric 120 substantially at the edge of liner 150 , eg, as indicated by reference arrow 152 . It is sized and dimensioned to extend to an edge around 150 and to the edge of the through hole defined by projection 88 as indicated by reference arrow 154 . In one aspect, this extension of the fabric 120 to the edge of the liner 150 may provide improved strength and durability to the liner 150 . In other aspects, the extension of the fabric 150 may not extend to the edge of the liner 150 , such as due to manufacturing or manufacturing tolerances, among other reasons, but still provides the liner 150 with desired strength and durability.

28 is a perspective view of a human head form 210 having a helmet or headgear 212 partially shown in cross-section including an outer helmet shell 214 and an inner fluid-filled liner 216 in accordance with an aspect of the present invention. to be. According to aspects of the present invention, the fluid filled liner 216 contains a fluid, such as oil, PDMS, diol, or one or more of any of the fluids disclosed herein, and includes a recess or hole 218 and a reinforcing element 220 . and a hollow structure made of an elastomeric material, such as liquid silicone rubber (LSR), comprising a region with 222 . The hollow structure material of the liner 216 may include any one or more of the materials disclosed herein, for example, a medical grade LSR such as silicone rubber sold under the True Skin® trademark.

In accordance with aspects of the present invention, the fluid in the liner 216 and the recess or hole 218 provides an effective means of dissipating at least a portion of the impact force experienced by the helmet 212, so that the helmet 212 wearer's head It is possible to minimize the transmission of impact force to the 29 is a perspective view of the human head form 210 and the fluid filled liner 216 shown in FIG. 28 with the outer helmet shell 214 removed to more clearly illustrate aspects of the present invention similar to FIG. 28 . .

In accordance with aspects of the present invention, the helmet shell 214 may be any helmet shell adapted to receive and/or retain the liner 216 , such as a retention strap, an ear, not shown in FIGS. 1-28 . It may have many of the features of a conventional helmet or headgear, such as a hole, trim piece and/or shell reinforcement. In one aspect the helmet shell 214 may be made of any suitable material, such as metal, plastic or even wood. However, typically helmet shell 214 may be made of plastic, eg, polycarbonate, such as a polycarbonate shell made by injection molding or an equivalent process. In one aspect, the shell 214 may be the helmet shown in US design patent 844,252 or US design patent 853,038.

In one aspect, regions of liner 216 with reinforcing elements 220 and 222 are positioned to withstand helmet impact, eg, to withstand helmet impact while dissipating the force and/or energy of impact into the liner, thus Reduce and/or minimize the impact of impact on the wearer's head. In one aspect, the location of the region of the liner 216 with the reinforcing elements 220 and 222 is positioned to optimize the energy distribution of the impact. In another aspect, the location of the region of the liner 216 with the reinforcing elements 220 and 222 is selected to optimize and/or enhance the structural integrity of the liner 216 . For example, in one aspect, the locations of reinforcing elements 220 and 222 and other reinforcing elements disclosed herein in the liner 216 are selected where the liner 216 is considered most likely to be subjected to an impact load.

28 and 29 , in accordance with one aspect of the present invention, the fluid filled liner 216 may include at least one reinforcing material (discussed below), such as the liner 216 during an expected load, such as an impact load. one or more reinforcing elements 220 and 222 comprising a material that enhances the structural integrity of the liner 216 to minimize or prevent structural damage to the liner 216 .

In accordance with aspects of the present invention, the liner 216 has the reinforcing elements disclosed herein, while the fluid filled liner and design and design disclosed in U.S. Patent No. 8,856,972 or pending U.S. Patent Application No. 15/833,747, the disclosures of which are incorporated herein by reference. The construction may be similar or the design and construction may be substantially the same. For example, in one aspect, the liner 216 may comprise any one of a fluid filled liner having one or more reinforcing regions 220, 222 as disclosed and disclosed in U.S. Patent No. 8,856,972 or pending U.S. Patent Application No. 15/833,747, and as disclosed herein. may include

30 is, for example, a perspective view of the fluid filled liner 216 shown in FIG. 29 when removed from the helmet 214 and the head form 210 disposed on the surface. 31 is a top view of the fluid filled liner 216 shown in FIG. 30 , FIG. 32 is a right elevation view of the fluid filled liner 216 shown in FIG. 31 , and the left elevation is a mirror image thereof. As shown, the impact dissipation liner 216 is a flexible, fluid impermeable enclosure having a top wall 246 , a bottom wall 248 , and a sidewall 250 between the top wall 246 and the bottom wall 248 . (217). In accordance with an aspect of the present invention, the liner 216 includes a plurality of cavities 251 extending between an upper wall 246 and a lower wall 248, each of the plurality of cavities 251 from an upper wall to a lower wall. has a cavity sidewall extending into

30-32 , in one aspect the liner 216 has a plurality of lobes or sections extending from a central portion 236 having a recess or hole 218 ( 228, 230, 232 and 234). For example, lobes 228 and 232 may be side lobes, lobe 234 may be a back lobe, and lobe 230 may be an anterior lobe of liner 216 . In accordance with aspects of the present invention, the lobes or sections 228 , 230 , 232 and 234 may be isolated or separated by a recess or cavity 238 . The lobes or sections 228 , 230 , 232 and 234 can be shaped and positioned, wherein when the liner 216 is placed on the helmet shell 214 , the recess or cavity 238 is substantially removed. and adjacent surfaces of the lobes 228 , 230 , 232 and 234 may be adjacent to each other to form a substantially continuous barrier. 29 , for example, when the liner 216 is placed on the helmet 214, the contact or bonding of the sections 228, 230, 232, and 234 may occur where the cavity 238 once appeared at the contact line ( 240) can be formed. In one aspect the contact between sections 228 , 230 , 232 and 234 may be continuous, while in another aspect there will be some separation between adjacent sections 228 , 230 , 232 and 234 along the line of contact 240 . considered to be possible.

30 and 31 , in accordance with aspects of the present invention, the liner 216 may include, for example, at least one, but typically, as disclosed herein having four reinforcing elements 220 , 222 , 224 and 226 . to include a plurality of reinforcement regions. According to one aspect, each lobe 228 , 230 , 232 and 234 may include one or more reinforcing elements, whereas in FIGS. 30-32 each lobe 228 , 230 , 232 and 234 is each a single reinforcing element. (220, 222, 224 and 226). In one aspect, the central portion 236 of the liner 216 may include one or more reinforcing elements.

FIG. 33 is a cross-sectional view of a portion of the fluid filled liner 216 shown in FIG. 31 , as viewed through section line 33-33 shown in FIG. 31 . The cross-sectional view shown in FIG. 33 includes a hole 218 having a sidewall 219 , such as a lobe 230 of the liner 216 having a reinforcing element 222 around the through hole. As shown in FIG. 33 , the liner 216 may include a hollow structure or enclosure 217 that typically contains a fluid 242 such as oil, PDMS, or any fluid disclosed herein, and may include an enclosure 217 . ) may typically have an upper wall 246 , a lower wall 248 , and a sidewall 250 between the upper and lower walls 246 and 248 . 33 , in one aspect, the reinforcing element 222 can be inserted into the top wall 246 , ie, the outer wall of the liner 216 is, for example, a material of the top wall 246 , such as an elastomer. It can be inserted into the material. However, it is contemplated that the reinforcing element 222 may be located anywhere on the top wall 246 , above the surface of the top wall 246 , and/or below the surface of the top wall 246 of the liner 216 . For example, as shown in FIG. 33 , the reinforcing element 222 may be located, for example, in a different material layer above the top wall 246 of the liner 216 .

In accordance with aspects of the present invention, reinforcing element 222 and any reinforcing element or fabric disclosed herein may provide enhanced strength and durability to the reinforcing region of a fabric sheet, such as liner 216, in accordance with aspects of the present invention. The liner 216 may include one or more sheets of fabric, which may provide improved protection, such as improved impact resistance or energy dissipation, to the surface adjacent the liner 216 .

In accordance with aspects of the present invention, reinforcing element 222 and any reinforcing element or fabric disclosed herein may comprise any woven, non-woven, knitted or non-knitted fabric or sheet material. In one aspect of the present invention, the reinforcing material 222 may be referred to as a “fabric” although any form of thin material, cloth or textile may be used for the reinforcing element 222 and provide enhancements to the liners disclosed herein. considered to be able to provide. In one aspect, the reinforcing element 222 may be any form of thin material made, such as by weaving, felting and/or knitting, for example, of natural and/or synthetic fibers and/or filaments. In one aspect, the reinforcing element 222 may be flexible, ie, it may be easily bent or deformed.

According to aspects of the present invention, reinforcing element 222 and any reinforcing element or fabric disclosed herein may have a thickness ranging from about 0.001 inches [in.] to about 0.25 inches, but typically from about 0.005 inches to about 0.050 inches. inches, such as in the range of about 0.010 inches to about 0.020 inches.

In one aspect, reinforcing element 222 and any reinforcing element or fabric disclosed herein may be materials made from natural materials, plastics, elastomers, or metals. For example, the reinforcing element 222 may be made of cellulosic fibers, such as silk fibers, wood fibers, rayon fibers, and/or carbon fibers. In other aspects, the reinforcing element 222 may be made of a metal sheet or metal fiber, such as a thin aluminum, steel or stainless steel sheet or woven metal filament. In one aspect, the reinforcing element 222 is made of one or more elastomeric or rubber materials, such as the following elastomers: natural polymers such as polyisoprene rubber or neoprene, thermoplastic elastomers, thermoplastic rubber and polyvinyl chloride, or ethylene propylene diene monomer (EPDM). ) may be made of one or more of a thin sheet or woven filament, such as a synthetic polymer such as rubber.

In one aspect, reinforcing element 222 , or any reinforcing element or fabric disclosed herein, may be made of glass fibers, such as chopped strand glass fibers and/or woven glass fibers. In one aspect, the reinforcing element 222 may be a woven fiberglass tissue or a woven fiberglass veil known in the art.

In an aspect, reinforcing element 222 , or any reinforcing element or fabric disclosed herein, may be made of carbon fibers, such as chopped strands and/or woven carbon fibers such as micro and/or nano fibers.

In one aspect, reinforcing element 222 and any reinforcing element or fabric disclosed herein may be made of a thin plastic sheet or film, or plastic fibers or filaments. For example, the reinforcing element 222 may be made of the following plastics: polyamide (PA), such as nylon, among other plastics; aramid polymers such as Nomex® or Kevlar® polymers; all polyethylene (PE), high density polyethylene (HDPE) and low density polyethylene (LDPE); polyethylene terephthalate (PET) such as Dacron® polymer; polypropylene (PP); polyester (PE); polytetrafluoroethylene (PTFE); polystyrene (PS); acrylonitrile butadiene styrene (ABS); polycarbonate (PC); or polyvinyl chloride (PVC), a thin sheet or thin fabric. For example, the reinforcing element 222 may include a combination of polyethylene terephthalate (PET) (eg, Dacron® PET), polyester, and an aramid polymer (eg, Nomex® aramid polymer).

In one aspect, reinforcing element 222 and any reinforcing element or fabric disclosed herein may be composed of fibers or filaments having a thickness, ie, denier or denier/filament. For example, in one aspect the reinforcement material 244 may have a denier/filament of about 40/24.

In one aspect, reinforcing element 222 and any reinforcing element or fabric disclosed herein may be comprised of fibers or filaments having a turn or twist per inch (TPI). For example, in one aspect the reinforcing element 222 may have a twist per inch of about 0.1 TPI to about 5.0 TPI, eg, about 0.5 TPI in the “Z twist” direction, or “0.5Z”.

In one aspect, reinforcing element 222 and any reinforcing element or fabric disclosed herein may be treated, such as refined, to remove undesirable materials such as dust, oil and/or grease. In one aspect, the reinforcing element 222 may be heat set to minimize shrinkage.

In one aspect, the reinforcing element 222 and any reinforcing element or fabric disclosed herein may be a fabric provided by Mohawk Fabric Company, Inc. of Amsterdam, New York. For example, in one aspect, the reinforcing element 222 may be made of a material sold under model number “SP 403” or equivalent.

34 is a top perspective view of a mold 260 that may be used to manufacture a portion of a fluid filled liner 216 having a reinforcing element 222 in accordance with an aspect of the present invention. Mold 260 may include a “B mold” used to form part of a liner in accordance with aspects of the present invention, which may include, for example, FIGS. 5-11 and related moorings, the entire disclosure of which is incorporated herein by reference. It may be combined with a portion of a liner made from "A mold" as disclosed in pending U.S. Provisional Patent Application No. 62/742,869.

34 , in this aspect, mold 260 is adapted to receive a curable or hardenable fluid (not shown), such as liquid silicone rubber (LSR). The mold 260 may include a surface 264 formed in a block, panel, or plate 266 , and may include, for example, a rim or peripheral barrier 268 surrounding the perimeter of the plate 266 , the rim 268 may function to retain the curable fluid introduced into mold 260 .

34 , mold 260 may include a plurality of projections 270 , such as a plurality of cylindrical projections, such as circular cylindrical, or rectangular cylindrical projections. As also shown in FIG. 34 , mold 260 typically has lobes or sections 272 , 274 , 276 and 278 corresponding to, for example, lobes 228 , 230 , 232 and 234 of liner 216 . It may take the form of a liner of any desired shape.

According to aspects of the present invention, mold 260 typically has at least one, but typically a plurality of recesses or depressions 280 positioned and shaped to receive a desired reinforcing element, such as a reinforcing fabric. , 282, 284 and 286). FIG. 35 is a detailed plan view of the mold 260 shown in FIG. 34 , identified by detail 35 in FIG. 34 .

34 and 35 , the recesses 280 , 282 , 284 and 286 are, for example, the use, application, shape and/or dimensions of the liner and the hole in the liner, such as the hole shown in FIGS. 28-33 . It can take on a wide variety of geometries depending on the location and dimensions of the projection 270 relative to 218 . In accordance with aspects of the present invention, recesses 280, 282, 284, and 286 may have a depth below surface 264 of between 0.01 inches and 2 inches, depending, for example, on the size and shape of the liner being formed; may have a depth below surface 264 of typically 0.010 inches to 0.25 inches, such as about 0.125 inches

36 is a plan view of reinforcing elements 288, 290, 292 and 294 that may be used with the mold 260 shown in FIGS. 34 and 35 to form aspects of the present invention. According to aspects of the present invention, the shape or contour of the reinforcing elements 288, 290, 292 and 294 may be any suitable, eg ensured by the shape of the recesses 280, 282, 284 and 286 shown in FIG. can take shape. As shown in FIG. 36 , the reinforcing elements 288 , 290 , 292 and 294 include recesses 280 , 282 , shown in FIG. 35 , including, for example, perforations or holes adapted to receive the protrusion 270 . 284 and 286). Reinforcing elements 288 , 290 , 292 and 294 may be made of any one or more materials disclosed herein from, for example, a fabric provided by Mohawk Fabric Company, Inc., and may have a thickness as disclosed herein, such as about 40 It can have a denier/filament of /24.

The size or external dimensions of reinforcing elements 288 , 290 , 292 and 294 may vary depending on the size and shape of the liner and helmet in which they will be used. For example, in one aspect, reinforcing elements 288 , 290 , 292 and 294 may have external dimensions or widths in the range of 0.25 inches to 12 inches, but typically between 2 inches and 6 inches. have.

FIG. 37 is a top view of one reinforcing element 292 shown in FIG. 36 . As typical of reinforcing elements 288 , 290 , 292 and 294 , the shape, eg, outer contour, of reinforcing element 292 is adapted to be received by recess 286 shown in FIGS. 34 and 35 , perforations or holes. 296 is sized and positioned to be received by projection 270 of recess 286 . For example, reinforcing element 292 may include curved lobes or lobes 298 and curved recesses 300 shaped and positioned to be received by curved lobes and recesses of recesses 286 of FIGS. 34 and 35 . can

38 is the mold shown in FIG. 34 having recesses 280, 282, 284 and 286 at least partially filled with a curable fluid 302, such as liquid silicone rubber (LSR), in accordance with an aspect of the present invention. A top perspective view of 260 . As shown, in one aspect, the curable fluid 302 may be introduced into the mold 260 by one or more nozzles 304 , although other conventional means may be used. 38 , in one aspect, at least some curable fluid 302 in preparation for placement of reinforcing elements 288 , 290 , 292 and 294 in recesses 280 , 282 , 284 and 286 . ) may be introduced into the recesses 280 , 282 , 284 and 286 of the mold 260 . In an aspect, reinforcing elements 288 , 290 , 292 and 294 may be introduced into recesses 280 , 282 , 284 and 286 prior to introduction of curable fluid 302 .

FIG. 39 shows recesses 280 , 282 , 284 and 286 having the two reinforcing elements 292 and 294 shown in FIG. 36 and at least partially filled with a curable fluid 302 in accordance with an aspect of the present invention. ) is a top perspective view of the mold 260 shown in FIG. 38 . In one aspect, reinforcing elements 292 and 294 may be positioned manually or by means of an automatic manipulator. As shown in FIG. 39 , according to one aspect, the reinforcing elements 292 and 294 may be immersed in a previously supplied curable fluid 302 and/or the additional curable fluid 302 may be For example, a curable fluid 302 may be provided after placement of the reinforcing elements 292 and 294 to ensure that they substantially cover the reinforcing elements 292 and 294 . In a similar manner, reinforcing elements 288 and 290 may be positioned in recesses 280 and 284 of mold 260 before or after introducing curable fluid 302 into recesses 280 and 284, respectively. have.

In accordance with aspects of the present invention, after disposing the curable material 302 and the reinforcing elements 288, 290, 292 and 294, an additional curable fluid 302 is applied to the mold 260, “Mold B”. may be introduced and then cured and/or uncured fluid 302 and mold 260 may be combined with a similar part, e.g., “Part A” made from “Mold A”, in accordance with aspects of the present invention. A liner may be formed. For example, in one aspect, this combination of Part A and Part B to form a liner is shown and described with respect to FIGS. 5-22 . After proper hardening or curing of the curable fluid 302 and creation of a liner having an inner cavity, the inner cavity is substantially filled with a fluid, such as by fluid injection, to form a fluid filled liner according to aspects of the present invention. can be formed substantially.

40 depicts a cured curable fluid formed by hardening or curing of the curable fluid 302 and removal from the B mold 260 shown in FIGS. 38 and 39 in accordance with an aspect of the present invention. 315) and a top view of a liner 310 having reinforcing elements 288, 290, 292 and 294 comprising corresponding A parts made of A mold. As shown, the impact dissipation liner 310 is a flexible, fluid impermeable enclosure having a top wall 313 , a bottom wall 315 , and a sidewall 317 between the top wall 313 and the bottom wall 315 . (311). In accordance with aspects of the present invention, the liner 310 includes a plurality of cavities 319 extending between an upper wall 313 and a lower wall 315, each of the plurality of cavities 319 from the upper wall to the lower wall. has a cavity sidewall extending into

41 is a perspective view of a portion of the liner 310 shown in FIG. 40 showing details of a reinforcement region having a reinforcement material 294 inserted in a cured curable fluid 315 in accordance with an aspect of the present invention. to be.

FIG. 42 shows a fluid filled liner having reinforcing elements 288, 290, 292 and 294 made from the liner 310 shown in FIG. 40 after introducing the fluid into the cavity of the liner 310 by, for example, injection. 320) is a plan view.

43 is a view of a helmet assembly 330 including a helmet shell 335 having the fluid filled liner 320 shown in FIG. 42 with reinforcing elements 288 , 290 , 292 and 294 in accordance with an aspect of the present invention. It is a bottom view.

43 also illustrates bodies 340 and 345 that may be mounted to the interior surface of a helmet shell 335 in accordance with an aspect of the present invention. In one aspect, body 340 and body 345 may provide at least some retention of liner 320 in helmet 335 , as disclosed, for example, in pending US Patent Application No. 15/833,747 . A body 340 , such as a circular cylindrical body, is connected to a hole 218 in the fluid filled liner 320 , such as a hole 218 in the reinforcing elements 288 , 290 , 292 and 294 , in the helmet 335 for the liner 335 . At least some of the holding force of 320 may be provided. The body 345 may be a polyhedral or polygonal cylindrical body, and may be connected to a peripheral surface of the fluid filled liner 320 to provide at least some retention of the liner 320 in the helmet 335 . The bodies 340 and 345 may be compressible bodies made of, for example, plastic foam.

In accordance with aspects of the present invention, the enclosures of liners and liner portions disclosed herein, such as liners 10 , 140 , 150 , 216 , 310 and 320 , are liquid silicone rubber, such as a cured, platinum cured LSR. liquid silicone rubber. In one aspect, the enclosure of the liners disclosed herein may include LSR sold under the trademark True Skin®; However, the enclosure of the liners disclosed herein may include any cured liquid silicone rubber (LSR). In one aspect, the cured liquid silicone rubber is a "medical grade" LSR known in the art, such as an LSR having, among other things, elastic, viscosity, "tactile" and/or antimicrobial properties desirable in aspects of the present invention. can

However, in one aspect liquid silicone rubber sold under the trademark True Skin® may be preferred. In one aspect, the enclosure disclosed herein is a 10 Shore A durometer (or durometer), disclosed in the CHT “Technical Data Sheet” [Rev-1, 8-16-17] for True Skin® 10, which is incorporated herein by reference. CHT's True Skin® 10 with In one aspect, the enclosure disclosed herein is a 20 Shore A durometer (or durometer), disclosed in the CHT “Technical Data Sheet” for True Skin® 20 [Rev-1, 8-16-17], which is incorporated herein by reference. CHT's True Skin® 20 with In one aspect, the enclosure disclosed herein is a 30 Shore A durometer (or durometer), disclosed in the CHT “Technical Data Sheet” [Rev-1, 8-16-17] for True Skin® 30, which is incorporated herein by reference. CHT's True Skin® 30 with

Any one of the enclosures and liners disclosed herein, known in the art, is a liquid produced when bonding two or more components, such as CHT True Skin liquid silicone rubber “A” and CHT True Skin liquid silicone rubber “B”. Made from silicone rubber, it can produce the desired liquid silicone rubber when cured.

It is also contemplated that aspects of the present invention may be made from other liquid silicone rubbers, such as LSR sold under the trademark SILBIONE® by Elkem Silicones of Lyon, France or equivalent. For example, in one aspect, one or more of the LSRs identified in the June 2018 "Silbione® Liquid Silicone Rubber (LSR) Elastomers" line card from Elchem, incorporated herein by reference, may be used in an aspect of the present invention.

In another aspect, the enclosure of the present invention may be made from an LSR sold by Dow Corning or equivalent.

In another aspect, the enclosure of any one of the liners disclosed herein may be made of LSR sold under ^{the trademark DRAGON SKIN™ of Smooth-On, Inc. or equivalent. For example, one or more of the LSRs identified in SmoothOn's Technical Bulletin "Dragon Skin TM} Series" having reference number 041619-JR, incorporated herein by reference, may be used in an aspect of the present invention.

In accordance with aspects of the present invention, a fluid (eg, liquid) contained within the enclosure of a liner disclosed herein, eg, liners 10, 140, 150, 216, 310 and 320, is incorporated into a polydimethylsiloxane fluid, such as CHT. polydimethylsiloxane fluid sold as a QM diluent by However, the fluid may include any polydimethylsiloxane fluid. However, in one aspect, polydimethylsiloxane fluids sold under the brand QM diluent may be preferred. In one aspect, the fluid enclosed in the enclosure of a liner disclosed herein is about 50 centipoise disclosed in the CHT “Technical Data Sheet” [Rev-3, 8/7/17] for QM Diluent 50, which is incorporated herein by reference. and QM Diluent 50 having a viscosity of (centipoise: cps). In one aspect, the fluid enclosed in the enclosure of a liner disclosed herein has a viscosity of about 100 cps as disclosed in the CHT “Technical Data Sheet” [Rev-3, 8/7/17] for QM Diluent 100, which is incorporated herein by reference. QM diluent 100 with In one aspect, the fluid enclosed in the enclosure of a liner disclosed herein has a viscosity of about 1000 cps as disclosed in the CHT “Technical Data Sheet” [Rev-3, 8/7/17] for QM Diluent 1000, which is incorporated herein by reference. QM diluent 1000 with In one aspect, the fluid enclosed in the enclosure of the liners disclosed herein may include QM Diluent 5000 having a viscosity of about 5000 cps, not identified in the “Technical Data Sheet”. It is contemplated that higher viscosity fluids, such as QM diluents having a viscosity greater than 5000 cps, may be used in embodiments of the present invention.

It is contemplated that fluids of different viscosities, such as QM diluents provided by CHT, may also be used, such as by suitably combining at least two fluids of known viscosities as is known in the art. Thus, in one aspect, polydimethylsiloxane fluids of different viscosities, such as CHT QM diluent, may be mixed or otherwise combined to provide a fluid having a viscosity of at least 50 cps that may be used as a fluid in aspects of the present invention. Similarly, in one aspect, polydimethylsiloxane fluids of different viscosities, such as CHT QM diluent, may be mixed or otherwise combined to provide a fluid having a viscosity of at least 100 cps that may be used as a fluid in aspects of the present invention. . In one aspect, polydimethylsiloxane fluids of different viscosities, such as CHT QM diluent, may be mixed or otherwise combined to provide a fluid having a viscosity of at least 500 cps that may be used as a fluid in aspects of the present invention. In one aspect, polydimethylsiloxane fluids of different viscosities, such as CHT QM diluent, can be mixed or otherwise combined with at least 1000 cps, at least 2000 cps, at least 3000 cps, at least 4000 cps, which can be used as a fluid in an aspect of the present invention; A fluid having a viscosity of at least 5000 cps, at least 6000 cps, or at least 8000 cps may be provided.

Aspects of the present invention provide a versatile impact dissipating liner for physical and structural protection. For example, when applied to head protection, aspects of the present invention may provide head protection in both low and high energy impacts, in any direction and at any one point in time. Also, in contrast to prior art head protection, aspects of the present invention have been tested and found to provide repeated impact protection, such as protection from multiple impacts. In addition to the energy absorbing function of aspects of the present invention, the lower profile properties of aspects of the present invention compared to the prior art provide a lower "lever arm" for any load, thereby reducing the head, neck and /or may provide the benefit of reducing the transmission of rotational or torsional loads to the spine For example, where the prior art is characterized by a thicker liner, eg, a head protection having a thickness of 2-3 inches, aspects of the present invention may be adapted to provide a liner thickness that is only about 1/2 inch thick. . As is known in the art, a reduction in thickness and thus a reduction in the impact torsion lever arm can significantly reduce torsional loads on a user's head, neck and/or spine.

From the foregoing, it can be seen from the foregoing that the present invention, in many aspects thereof, provides an impact dissipation liner, a method of making an impact dissipation liner, helmets and headgear having an impact dissipation liner, an arrangement, a liner, and a head and other body structures or structures where protection is desired A method of protecting other common non-physical structures is provided. Again, while aspects of the present invention have been shown and described in connection with headgear and helmets, it is contemplated that aspects of the present invention may be used with any barrier, structure, or any impact dissipating liner disclosed herein. In one aspect, a barrier for motor sports may include one or more of the shock dissipation liners disclosed herein, such as a barrier or wall of a race track (eg, auto racing track) or race course (eg, motocross course), and the like. have.

The terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the present disclosure. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly dictates otherwise. Also, the terms "comprises", "comprising," "including," and/or "having," when used herein, include defined features, integers, steps, It is understood to specify the presence of an action, element, and/or component, but does not preclude the presence or addition of one or more other features, integers, steps, actions, elements, components, and/or groups thereof.

The description of the present disclosure has been presented for purposes of illustration and description, but is not intended to be exhaustive or limiting of the disclosure in the form disclosed. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the present disclosure. The present embodiments were chosen and described so as to best explain the principles of the disclosure and practical application, and to enable those skilled in the art to understand the disclosure of various embodiments having various modifications as are suited to the particular use contemplated.

This written description, by way of illustration, discloses the present invention, including the best mode contemplated, and provides those skilled in the art, including making and using any apparatus or system, and performing any integrated method; to make the present invention practiced. The patentable scope of the invention is defined by the claims, and may include other examples that may occur to those skilled in the art. Such other examples are within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. it is intended to be

Claims (42)

An impact dissipation helmet liner (10, 140, 150, 216, 310, 320) comprising:
Top walls 12, 143, 153, 246, 313, opposing bottom walls 14, 145, 155, 248, 315, and side walls 18, 149, 159, 250 extending between the top and bottom walls , 317 ); a flexible, fluid impermeable enclosure ( 11 , 141 , 151 , 317 , 311 );
a fluid (24, 242) contained in the enclosure (11, 141, 151, 317, 311); and
fabric sheets (20, 120, 222) positioned on at least one of the upper wall and the lower wall
An impact dissipating helmet liner (10, 140, 150, 216, 310, 320) comprising: According to claim 1,
The liner further includes a plurality of cavities (17, 147, 157, 251, 319) between the upper wall and the lower wall, each of the plurality of cavities defining a cavity sidewall extending from the upper wall to the lower wall. An impact dissipating helmet liner (10, 140, 150, 216, 310, 320). According to claim 1,
wherein the fabric sheet 20, 120, 222 comprises one of a woven fabric, an unwoven fabric, and a knitted fabric, an impact dissipating helmet liner 10, 140, 150, 216, 310 , 320). 4. The method of claim 3,
The fabric sheet (20, 120, 222) will comprise a knitted fabric comprising one of polyethylene terephthalate (PET), polyester and aramid polymer, impact dissipation helmet liner (10, 140, 150, 216, 310, 320) ). According to claim 1,
The flexible, fluid impermeable enclosure (11, 141, 151, 317, 311) includes a central portion (236) and a plurality of lobes (228, 230, 232, 234) extending therefrom, the central portion (236) and the portion and the plurality of lobes are adapted to conform to the shape of the inner surface of the helmet. 6. The method of claim 5,
wherein the plurality of lobes (228, 230, 232 and 234) define a cavity (238) extending radially between adjacent lobes. ). According to claim 1,
wherein said flexible, fluid impermeable enclosure (11, 141, 151, 317, 311) comprises liquid silicone rubber. According to claim 1,
and the fluid (24, 242) comprises a liquid. 9. The method of claim 8,
wherein the liquid comprises one of liquid silicone rubber, polydimethylsiloxane and polyol. According to claim 1,
The helmet liner is a baseball catcher's helmet, a baseball batter's helmet, a softball catcher's helmet, a softball batter's helmet, a hockey helmet, a hockey goalie helmet, a motorcycle helmet, a motocross helmet, a ski helmet, a snowboard helmet, a skateboard helmet, lacrosse An impact dissipation helmet liner, comprising a liner for at least one of a helmet, a bicycle helmet, a jockey helmet, an official helmet, a medical protective helmet, a rock or ice climbing helmet, a mountaineering helmet, a football helmet, a construction helmet, and a military helmet ( 10, 140, 150, 216, 310, 320). A helmet (335) having the impact dissipating helmet liner (10, 140, 150, 216, 310, 320) of claim 1. 12. The method of claim 11,
the helmet (335) comprising a helmet shell comprising the impact dissipating helmet liner (10, 140, 150, 216, 310, 320). An impact dissipation liner (10, 140, 150, 216, 310, 320) comprising:
Top walls 12, 143, 153, 246, 313, opposing bottom walls 14, 145, 155, 248, 315, and side walls 18, 149, 159, 250 extending between the top and bottom walls , 317 ); a flexible, fluid impermeable enclosure ( 11 , 141 , 151 , 317 , 311 );
a fabric sheet (20, 120, 222) positioned on at least one of the upper wall and the lower wall; and
fluid (24, 242) contained in the enclosure
An impact dissipation liner (10, 140, 150, 216, 310, 320) comprising: 14. The method of claim 13,
The liner further comprises a plurality of cavities (17, 147, 157, 251, 319) extending between the upper wall and the lower wall, each of the plurality of cavities extending from the upper wall to the lower wall. an impact dissipating liner (10, 140, 150, 216, 310, 320) having sidewalls. 14. The method of claim 13,
wherein the fabric sheet (20, 120, 222) comprises one of a woven, non-woven and knitted fabric. 16. The method of claim 15,
The fabric sheet (20, 120, 222) will comprise a knitted fabric comprising polyethylene terephthalate (PET), polyester and aramid polymer, impact dissipation liner (10, 140, 150, 216, 310, 320). 14. The method of claim 13,
wherein said flexible, fluid impermeable enclosure (11, 141, 151, 317, 311) comprises liquid silicone rubber. 14. The method of claim 13,
and the fluid (24, 242) comprises a liquid. 19. The method of claim 18,
and the liquid comprises one of liquid silicone rubber, polydimethylsiloxane and polyol. 14. The method of claim 13,
wherein the liner comprises one of a helmet liner, a head gear liner, a body armor liner, a body padding liner, a barrier liner, a wall liner, and a surface liner. 320). A method of making an impact dissipating liner (10, 140, 150, 216, 310, 320) comprising:
providing a first mold (50, 100, 260) adapted to receive a first curable fluid (52, 102), said first mold comprising a mold cavity having a lower surface (54, 104, 264) and having a plurality of projections (60, 110, 270) from said lower surface;
introducing the first curable fluid 102 and fabric sheet 62 , 120 , 282 into the first mold 50 , 100 , 260 such that the first mold is at least partially with the first curable fluid charging with;
introducing a second curable fluid into the first mold (50, 100) to at least partially cover the lower surface (54, 104, 264) with the second curable fluid;
allowing the first curable fluid to cure in the first mold and allowing the second curable fluid to cure at the lower surface to create an at least partially cured first liner portion 46 to do;
joining the first liner portion (46) with a second liner portion (52) portion to form a fluid impermeable enclosure (10, 216); and
introducing a fluid (24) into the fluid impermeable enclosure (10, 216) to provide the impact dissipation liner;
A method of manufacturing an impact dissipation liner comprising: 12. The method of claim 11,
said first mold (50, 100, 260) comprising at least one recess (280, 282, 284, 286) in said lower surface (54, 104, 264);
and introducing the fabric sheet (62, 120, 282) into the first mold comprises positioning the fabric sheet in the at least one recess in the lower surface. 23. The method of claim 22,
introducing the first curable fluid and the fabric sheet 62 , 120 , 282 into the at least one recess sequentially first introduces the first curable fluid into the at least one recess and a second comprising introducing the fabric sheet into the at least one recess. 22. The method of claim 21,
wherein the fabric sheet (62, 120, 282) comprises one of a woven, non-woven and knitted fabric. 22. The method of claim 21,
wherein the fabric sheet (62, 120, 282) comprises a knitted fabric comprising polyethylene terephthalate (PET), polyester and aramid polymer. 22. The method of claim 21,
and coupling the first liner portion with the second liner portion comprises sealing a peripheral edge of the first liner portion with a peripheral edge of the second liner portion. 22. The method of claim 21,
and the second curable fluid comprises the first curable fluid. 22. The method of claim 21,
wherein said plurality of projections (60, 110, 270) from said lower surface comprises a plurality of cylindrical projections. 29. The method of claim 28,
wherein the plurality of cylindrical protrusions (60, 110, 270) comprises a plurality of circular cylindrical protrusions. 22. The method of claim 21,
wherein the first curable fluid comprises liquid silicone rubber. 22. The method of claim 21,
and introducing the fluid into the fluid impermeable enclosure is effected by injecting the fluid into the fluid impermeable enclosure. 22. The method of claim 21,
coupling the first liner portion with the second liner portion comprises:
providing a second mold adapted to receive a third curable fluid, the second mold having a surface and a plurality of cylindrical recesses in the surface;
introducing the third curable fluid into the second mold to at least partially fill the first mold, including at least partially filling each of the plurality of recesses;
causing the first curable fluid to cure in each of the plurality of recesses and in at least a portion of the surface of the first mold to create an at least partially cured second liner portion; and
removing the at least partially cured second liner portion from the second mold, the at least partially cured second liner portion having a flexible sheet and a plurality of protrusions from the flexible sheet;
and manufacturing the second liner portion by a method comprising: A method of making an impact dissipating liner (10, 140, 150, 216, 310, 320) comprising:
providing a first mold adapted to receive a first curable fluid, the first mold having a surface, a plurality of projections from the surface, and a plurality of recesses, each of the plurality of recesses comprising: around one of the plurality of protrusions -;
introducing the first curable fluid into the first mold to at least partially fill the first mold, including at least partially filling each of the plurality of recesses;
causing the first curable fluid to cure in each of the plurality of recesses and in at least a portion of the surface of the first mold, thereby creating an at least partially cured first liner portion;
removing the at least partially cured first liner portion from the first mold, the at least partially cured first liner portion having a flexible sheet and a plurality of protrusions from the flexible sheet;
providing a second mold adapted to receive a second curable fluid, the second mold having a surface and a plurality of protrusions from the surface;
introducing a fabric sheet into at least a portion of the surface of the second mold, the fabric sheet having a hole, each hole positioned and sized to receive one of the protrusions from the surface of the second mold is determined -;
introducing the second curable fluid into the second mold to at least partially fill the second mold and at least partially cover the fabric of the second mold;
introducing the at least partially cured first liner portion into the second mold while the second curable fluid in the second mold is at least partially uncured, the at least partially cured the distal ends of the plurality of protrusions of the first liner portion contact the at least partially uncured second curable fluid in the second mold; and
causing the second curable fluid to cure, forming a second flexible sheet attached to the distal end of the plurality of protrusions of the at least partially cured first liner portion, and forming a fluid impermeable enclosure to do; and
introducing a fluid into the fluid impermeable enclosure to provide the impact dissipation liner;
A method of manufacturing an impact dissipation liner comprising: 34. The method of claim 33,
wherein the fabric sheet (60, 110, 270) comprises one of a woven fabric, a non-woven fabric, and a knitted fabric. 34. The method of claim 33,
The method of claim 1, wherein the fabric sheet comprises a knitted sheet comprising polyethylene terephthalate (PET), polyester and aramid polymer. 34. The method of claim 33,
The method of making the impact dissipating liner further comprises sealing a peripheral edge of the at least partially cured first liner portion with a peripheral edge of the second flexible sheet of the second curable fluid. . 37. The method of claim 36,
and sealing is performed while allowing the second curable fluid to cure. 134. The method of claim 133,
and wherein said plurality of recesses of said first mold comprise cylindrical recesses. 39. The method of claim 38,
wherein the plurality of cylindrical recesses comprises a circular cylindrical recess. 34. The method of claim 33,
wherein the first curable fluid is substantially the same as the second curable fluid. 41. The method of claim 40,
wherein the first curable fluid and the second curable fluid comprise liquid silicone rubber. 34. The method of claim 33,
and introducing the fluid into the fluid impermeable enclosure is effected by injecting the fluid into the fluid impermeable enclosure.

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