WO2025035207A1 - Casque de protection doté d'une cage optionnelle - Google Patents

Casque de protection doté d'une cage optionnelle Download PDF

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Publication number
WO2025035207A1
WO2025035207A1 PCT/CA2024/051050 CA2024051050W WO2025035207A1 WO 2025035207 A1 WO2025035207 A1 WO 2025035207A1 CA 2024051050 W CA2024051050 W CA 2024051050W WO 2025035207 A1 WO2025035207 A1 WO 2025035207A1
Authority
WO
WIPO (PCT)
Prior art keywords
outer shell
inner shell
shell
cage
resilient
Prior art date
Application number
PCT/CA2024/051050
Other languages
English (en)
Inventor
Tory Weber
Eric Lemieux
Martin Chambert
Michel Chiasson
Mariane BOISVERT-VALENCIA
Original Assignee
Vanquish Hockey Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Vanquish Hockey Limited filed Critical Vanquish Hockey Limited
Publication of WO2025035207A1 publication Critical patent/WO2025035207A1/fr

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Classifications

    • A—HUMAN NECESSITIES
    • A42—HEADWEAR
    • A42B—HATS; HEAD COVERINGS
    • A42B3/00—Helmets; Helmet covers ; Other protective head coverings
    • A42B3/04—Parts, details or accessories of helmets
    • A42B3/06—Impact-absorbing shells, e.g. of crash helmets
    • A42B3/062—Impact-absorbing shells, e.g. of crash helmets with reinforcing means
    • A42B3/063—Impact-absorbing shells, e.g. of crash helmets with reinforcing means using layered structures
    • A42B3/064—Impact-absorbing shells, e.g. of crash helmets with reinforcing means using layered structures with relative movement between layers

Definitions

  • the present invention relates to protective articles, such as a helmet, of the type including an inner shell and an outer shell supported for resilient movement relative to the inner shell.
  • the present invention further relates to a cage for a protective sports helmet to be worn while playing a sport in which the cage provides impact protection from projectiles while allowing the wearer to see through voids in the cage.
  • Protective helmets for example of the type worn by goalies in the sport of hockey, typically comprises a rigid outer shell having a minimal lining of resilient material arranged to be supported directly against the head of the user. In the event of puck impacts, or other impacts during play of the game of hockey, the impacts tend to be transmitted through minimal lining of resilient material to the head of the user causing disorientation to the goalie and/or a possible concussion type injuries.
  • the helmets worn by goalies also typically include a cage portion which spans over the eye region to protect the face of the user while allowing visibility through the cage. Impacts the cage are also commonly transmitted through the cage to the outer shell and can also result in possible concussion type injuries.
  • a protective helmet comprising: an inner shell arranged to be worn on a head of a user; an outer shell arranged to be mounted overtop of the inner shell so as to cover a top, a forehead, and laterally opposing sides of the user; and a resilient coupling supporting the outer shell on the inner shell such that the outer shell is spaced radially outward from the inner shell and supporting the outer shell for resilient movement relative to the inner shell responsive to an impact to the outer shell.
  • the use of an inner shell and a coupling arrangement that supports the outer shell spaced radially outward from the inner shell provides space and accommodation for impact absorbing features under the outer shell to reduce the transmission of impacts from the outer shell to the head of the user and to reduce rotational and angular forces to the brain of the user.
  • the resilient coupling may be formed by three-dimensional printing integrally together with at least one of the inner shell and the outer shell.
  • the inner shell, the outer shell and the resilient coupling are formed integrally together with one another as a uniform body by three-dimensional printing.
  • the resilient coupling may include a plurality of first elements formed by three- dimensional printing integrally together with the inner shell and a plurality of second elements formed by three-dimensional printing integrally together with the outer shell, the first coupling elements being selectively coupled to the second coupling elements to define the resilient coupling between the inner shell and the outer shell.
  • one of the first and second elements comprises sockets and another of the first and second elements comprises protrusions arranged to be received in the sockets respectively to define the resilient coupling.
  • the protrusions may be selectively retained in the sockets by a resilient snap-fit arrangement.
  • each protrusion may be linearly slidable within a respective one of sockets, in which each socket further comprises a resilient element therein which is resiliently deformed by sliding movement of the protrusion within the socket in response to an impact to the outer shell.
  • each socket Preferably at least some of the sockets are oriented in a different direction than one of more adjacent ones of the sockets.
  • the resilient coupling may be arranged to provide a stepped increase in resistance to movement between the inner shell and the outer shell in response to increasing deflection between the inner shell and the outer shell.
  • the resilient coupling may include (i) a plurality of first resilient elements providing resistance to movement between the inner shell and the outer shell in response to a first deflection amount, and (ii) a plurality of second resilient elements providing resistance to movement between the inner shell and the outer shell only response to a second deflection amount greater than the first deflection amount.
  • the outer shell may comprise a plurality of shell sections interlocked with one another so as to be movable relative to one another in a pivoting or folding manner for example.
  • the shell sections are interlocked for pivotal movement relative to one another, there may be provided stops on the shell sections that engage one another to limit relative pivotal movement between the shell sections to a prescribed range of angular deflection.
  • the resilient coupling may further comprise a lattice structure formed by three dimensional printing and occupying a cavity between the inner shell and the outer shell.
  • the outer shell comprises a first rigid material
  • the inner shell comprises a second rigid material which is less rigid than the first rigid material
  • the resilient coupling comprises a plurality of struts formed of resilient material.
  • the helmet may further comprise a liner supported along an interior of the inner shell to be worn against the head of the user, in which the inner shell and the liner are formed by three dimensional printing from dissimilar materials such that the inner shell is more rigid than the liner.
  • integral connectors may be formed integrally by three dimensional printing together with at least one of the inner shell and the liner in which the integral connectors being arranged to releasable couple the liner to the inner shell.
  • the releasable connectors may comprise sockets on one of the inner shell and the liner and protrusions on another of the inner shell and the liner, wherein the protrusions are selectively retained in the sockets by a resilient snap-fit arrangement.
  • the liner includes may further include strap cavities formed internally therein by three dimensional printing of the liner, in which the strap cavities receive helmet straps extending therethrough.
  • the liner may also include electronic cavities formed internally therein by three dimensional printing of the liner in which the electronic cavities receive electronic hardware therein.
  • the outer shell may include a plurality of ventilation openings formed therein and a plurality of structural members spanning across the ventilation openings so as to allow air to pass between the structural members in which the structural members are formed by three- dimensional printing integrally together with the outer shell.
  • the outer shell may include a plurality of helmet strap connectors mounted thereon and arranged to connect helmet straps to the outer shell, in which the helmet strap connectors are formed by three-dimensional printing integrally together with the outer shell.
  • the outer shell preferably includes a cage supported thereon so as to be arranged to span over eyes of the user in which the cage is supported on the outer shell by cage connectors and the cage connectors are formed by three-dimensional printing integrally together with the outer shell.
  • the outer shell may includes at least one accessory mount arranged to mount a helmet accessory externally on the outer shell in which said at least one accessory mount is formed by three-dimensional printing integrally together with the outer shell.
  • the outer shell may include three dimensional indicia formed thereon in which the indicia is formed by three-dimensional printing integrally together with the outer shell.
  • the outer shell includes a cage supported thereon so as to be arranged to span over at least part of a facial area of the user in which the cage may be formed by three- dimensional printing integrally together with the outer shell.
  • the cage may comprise a plurality of bars mounted in an intersecting manner to define the cage in which at least one of the bars varies in shape, cross sectional size, and/or angular orientation about the longitudinal axis along a length of the bar. More particularly, when one of the bars has a profile which is elongated along a transverse axis, the transverse axis varies in orientation about a longitudinal axis of the bars along a length of the bar.
  • At least one of the intersections preferably includes two of the bars intersecting one another in a common plane at the intersection.
  • some of the bars of the cage may be shaped to define a resilient section formed therein in which the resilient section is formed by three-dimensional printing integrally together with the cage, and in which the resilient section is resiliently deformable responsive to an impact.
  • the resilient sections of the cage are preferably located in the peripheral portion of the cage.
  • some of the bars may be shaped to define a beam profile having a greater resistance to bending in a first radial direction than a second radial direction relative to a longitudinal axis of the beam profile.
  • the beam profile has a greater resistance to bending transversely to a plane of the cage than bending within a plane of the cage.
  • Some of the bars of the cage may comprise a hollow frame member.
  • the resilient movement between the shells preferably includes a rotational movement of the outer shell relative to the inner shell about a center of rotation located within a boundary of the inner shell, a radial movement of the outer shell relative to the inner shell, and/or a translational movement of the outer shell relative to the inner shell.
  • the outer shell may be a three-dimensionally printed structure comprising a unitary body of open lattice material.
  • the inner shell is preferably formed of a rigid material and is arranged to span at least the forehead of the user, and/or at least the temporal regions of the user.
  • the outer shell and the inner shell are preferably each arranged to cover a jaw of the user and each include a central viewing portion arranged for alignment with eyes of the user which remains open for visibility.
  • the outer shell may be supported for translational movement along a longitudinal axis extending between the front and an opposing rear of the helmet.
  • the outer shell is preferably biased forwardly to return to a neutral position relative to the inner shell in response to being deflected rearwardly relative to the inner shell by an impact.
  • the outer shell may be movable along the longitudinal axis relative to the inner shell from the neutral position rearwardly by a greater distance than forwardly.
  • the helmet may further include a plurality of tracks fixed onto a first shell among the inner shell and the outer shell, and a plurality of followers fixed onto a second shell among the inner shell and the outer shell, wherein the followers are slidably coupled to the tracks respectively to define said translational movement.
  • Each follower may be radially compressible transversely to the longitudinal axis such that the resilient movement includes a radial movement of the outer shell relative to the inner shell.
  • Each track may comprise a groove in which each follower has a head having a profile which mates with a profile of the groove to retain the head within the groove while enabling longitudinal sliding of the head along the groove.
  • the inner shell may be arranged to span at least part of a jaw of the user.
  • the inner shell also includes a central opening in alignment with the central viewing portion wherein the inner shell extends about a full perimeter of the central opening.
  • the resilient coupling arrangement between the outer shell and the inner shell may be located only at a top and sides of the helmet.
  • the resilient coupling arrangement between the outer shell and the inner shell may be located only rearward of a temporal region of the inner shell.
  • a cage arranged for use with a helmet, the cage comprising: a plurality of bars mounted in an intersecting manner to define a boundary of the cage arranged to span over at least part of a facial area of the user when the cage is supported on the helmet; wherein the bars being formed integrally together with one another by three- dimensional printing.
  • the cage may comprise a plurality of bars mounted in an intersecting manner to define the cage in which at least one of the bars varies in shape, cross sectional size, and/or angular orientation about the longitudinal axis along a length of the bar. More particularly, when one of the bars has a profile which is elongated along a transverse axis, the transverse axis varies in orientation about a longitudinal axis of the bars along a length of the bar.
  • At least one of the intersections preferably includes two of the bars intersecting one another in a common plane at the intersection.
  • some of the bars of the cage may be shaped to define a resilient section formed therein in which the resilient section is formed by three-dimensional printing integrally together with the cage, and in which the resilient section is resiliently deformable responsive to an impact.
  • the resilient sections of the cage are preferably located in the peripheral portion of the cage.
  • some of the bars may be shaped to define a beam profile having a greater resistance to bending in a first radial direction than a second radial direction relative to a longitudinal axis of the beam profile.
  • the beam profile has a greater resistance to bending transversely to a plane of the cage than bending within a plane of the cage.
  • Some of the bars of the cage may comprise a hollow frame member.
  • an article of protective equipment to be worn on a body part of a user comprising: an inner shell including a concave interior side arranged to be worn against the body part of the user and a convex exterior side; an outer shell arranged to be mounted overtop of the inner shell so as to cover the inner shell, the outer shell including a concave interior side and a convex exterior side; and a resilient coupling extending between the convex exterior side of the inner shell and the concave interior side of the outer shell such that the outer shell is spaced radially outward from the inner shell, the outer shell being supported by the resilient coupling for resilient movement relative to the inner shell responsive to an impact to the outer shell.
  • Figure l is a side elevational view of a protective sports helmet according to one aspect of the present invention.
  • Figure 2 is a perspective view of the inner shell of the helmet, shown with the outer shell removed for illustrative purposes according to the helmet of Figure 1;
  • Figure 3 is side elevational view of the inner shell and rear cap of the helmet, shown with the outer shell removed according to the helmet of Figure 1;
  • Figure 4 is a front elevational view of the inner shell, shown with the outer shell removed according to the helmet of Figure 1;
  • Figure 5 is a sectional view of a portion of the coupling arrangement between the inner and outer shells of the helmet according to the helmet of Figure 1;
  • FIG. 6 is a side elevational view of the helmet in which the coupling arrangement is represented schematically for illustrative purposes according to the helmet of Figure 1;
  • Figure 7 is a perspective view of a further embodiment of the sports helmet according to the present invention.
  • Figure 8 is a perspective view of yet another embodiment of the sports helmet according to the present invention.
  • Figure 9 are front and sectional views of one embodiment of the cage for a sports helmet on a right side of the image compared to a prior art cage on a left side of the image;
  • Figure 10 is a partly sectional view of one embodiment of the resilient coupling for a helmet according to the present invention.
  • Figure 11 is a partly sectional view of another embodiment of the resilient coupling for a helmet according to the present invention.
  • Figure 12 is a partly sectional view of a further embodiment of the resilient coupling for a helmet according to the present invention.
  • Figure 13 is a partly sectional view of yet another embodiment of the resilient coupling for a helmet according to the present invention.
  • Figure 14 is a sectional view of two outer shell sections coupled for relative movement according to a further embodiment of the helmet;
  • Figure 15 is a perspective view of various exemplary features incorporated into the bars of the cage according to various embodiments of the helmet according to the present invention.
  • Figure 16 is a sectional view of one embodiment of integral connectors between the liner and the inner shell of the helmet according to the present invention
  • Figure 17 is a sectional view of another embodiment of integral connectors between the liner and the inner shell of the helmet according to the present invention
  • Figure 18 is a sectional view of a further embodiment of integral connectors between the liner and the inner shell of the helmet according to the present invention.
  • Figure 19 is a further embodiment of the helmet according to the present invention in the form of an aerodynamic bicycle helmet.
  • the protective article 10 typically comprises a helmet to be worn on the head of a user; however, the features of the protective article 10 described herein may also be applicable to a variety of other types of protective equipment that typically incorporate hard shells therein such as a protective cup or jock, elbow caps, shoulder caps and knee caps for example.
  • helmets including a hockey goalie mask, a hockey player helmet, a lacrosse helmet, a baseball batting helmet, a ski helmet, a bicycle helmet with or without a chin protector, a football helmet, a cricket helmet, military helmets, safety helmets including construction helmets, and automotive type helmets used in automotive racing, motorcycling or motocross for example.
  • the article generally includes a liner 100 worn against the body or head of the user in which the liner is formed of a resilient or semirigid material which may be manufactured by additive manufacturing or three- dimensional printing of a thermoplastic polyurethane material or other resilient printable plastic and foam materials for example.
  • the article further includes an inner shell 102 that at least partially or fully covers the liner. More particularly the inner shell 102 is a rigid shell that is more rigid than the liner 100 and which is generally spherical or semi-spherical in shape so as to include a concave interior side worn against the user and a convex exterior side.
  • the article also includes an outer shell 104 which fully covers the inner shell 102 and which is formed of a rigid material that may be similar to the inner shell, more rigid than the inner shell, or less rigid than the outer shell.
  • Each of the inner shell and the outer shell may be formed by three- dimensional printing from suitable printable materials including thermoplastics or various metals; however, in some embodiments only one of the shells is printed and the other shell is formed by other techniques including injection or compression molding for example.
  • the printed features described in the following would be incorporated integrally into the printed shell when only one of the shells is printed.
  • the outer shell 104 closely follows the shape of the inner shell so as to include a concave interior side facing towards the inner shell and a convex exterior side forming the exterior of the article.
  • the article includes a resilient coupling 106 coupled between the convex exterior of the inner shell 102 and the concave interior of the outer shell 104 so as to span the radial gap between the inner and outer shells.
  • the resilient coupling is formed of a resilient or semirigid three-dimensional printed material.
  • the resilient coupling 106 is typically printed integrally, seamlessly and continuously with one or both of the inner shell 102 and the outer shell 104.
  • the connecting elements between the inner and outer shells which define the resilient coupling are suitably shaped and configured to allow various relative movements between the outer shell and the inner shell in response to impacts.
  • the resilient coupling allows relative rotation of the outer shell relative to the inner shell about a centre of rotation typically located within the interior boundary of the inner shell.
  • the resilient coupling 106 also allows radial compression thereof as the outer shell is compressed radially inwardly towards the inner shell.
  • the resilient coupling 106 allows translational movement of the outer shell relative to the inner shell along an axis extending through the helmet, for example a longitudinal axis extending from the front to the back of the helmet, a lateral axis extending side to side across the helmet, or any other axis along which impacts may be received.
  • the article further relate to a helmet including a cage 108.
  • the cage 108 typically comprises a plurality of rigid bars 110 which are coupled to one another in an intersecting manner to define a boundary surface that spans over part of or the entirety of the facial area of the user when the cage is supported on the helmet.
  • the cage 108 may be formed integrally together with the outer shell of the helmet or may be subsequently mounted onto the helmet.
  • all of the bars 110 of the cage 108 are manufactured together as a single body that is seamless, unitary, and continuous of the same material throughout by being three dimensionally printed as a single body by itself or together with the outer shell of the helmet.
  • the individual bars of the cage 108 vary in configuration along a longitudinal axis of the bar corresponding to the length of the bar.
  • the bars may vary in configuration in various manners to optimize the performance thereof.
  • the bars vary in cross-sectional size so as to be thicker where more protection is desired and thinner where less protection is required or where improved lines of sight are desired in alignment with the eye area of the user for example.
  • the cross-sectional shape of the bar varies along the length for similar reasons to improve the performance or the visibility through the cage for example.
  • the shape and size of the cross-section of a bar may remain consistent, but the angular orientation is varied about the longitudinal axis along the length of the bar.
  • some of the bars in alignment with the eye area of the user may have a cross-sectional shape that is elongated along one transverse axis, for example an elliptical shape that is elongated along a major transverse axis.
  • the transverse axis may be oriented more horizontally than vertically in the eye area to minimize the vertical thickness of the bar at the lines of sight of the user; however, the orientation of the transverse axis may vary towards the periphery of the cage for other performance benefits or to simplify mounting arrangements, or to simplify the integration of the bars with the outer shell of the helmet.
  • the bars 110 of the cage 108 may be manufactured with a hollow tubular shape to reduce weight while optimizing resistance against bending.
  • the cross-sectional shape may be optimized to define a beam profile that is more resistant to bending in one direction than another.
  • the cross-sectional shape may define an I-beam with parallel flanges and a connecting web between the parallel flanges.
  • the beam profile may be specifically oriented so that there is greater resistance to bending transversely to a plane or boundary surface of the cage than bending of the bar within the boundary or plane of the cage.
  • the bars are thus best suited to resisting deformation from impacts directed at the cage perpendicularly to the plane or boundary of the cage while maximizing visibility through the cage where strength is less required.
  • the bars 110 intersect one another at one or more intersections 112
  • the bars at each intersection preferably lie in a common plane with one another at the intersection rather than the bars being separately formed and subsequently overlapping one another in the manner of construction of conventional helmet cages. Forming the bars at each intersection 112 to line a common plane is readily accomplished when the cage is manufactured by three dimensional printing.
  • some of the bars 110 of the cage may include resilient sections 114 incorporated therein and which are formed integrally together with the remainder of the cage by three-dimensional printing.
  • the cage includes a main portion 116 generally spanning the central area and eyes of the facial area of the user, and a peripheral portion 118 at opposing sides of the main portion 116 and which serve to connect the main portion to the outer shell of the helmet.
  • the resilient sections 114 are preferably formed in the peripheral portion 118 of the cage near the terminal ends of the bars where the bars join the outer shell.
  • the bar is shaped to be formed of thinner material or material which is formed into a helical or sinusoidal path to define a spring like structure where the bar of the cage is more resilient than the remaining rigid bar sections.
  • the resilient sections preferably function as a linear spring aligned along the longitudinal axis of the bar when the bar extends primarily in a forward and backward direction relative to the helmet at the attachment of the cage to the outer shell at opposing sides of the helmet.
  • impacts to the front of the cage cause the resilient sections 114 to be linearly recoiled and then resiliently spring back after the impact to absorb some of the impact.
  • the outer shell may include cage connectors 120 that are integrally formed on the outer shell of the helmet about the periphery of the viewing area that is covered by the cage.
  • the cage connectors 120 can be formed together with the outer shell during three-dimensional printing of the outer shell so as to be formed seamlessly and of the same material with the remainder of the outer shell.
  • the cage connectors 120 are formed as a socket which receive the end portions of respective ones of the bars of the cage therein so that the cage bars each function as a hinge pin defining a lateral hinging axis extending across the top of the cage about which the cage is pivoted when recoiling in response to an impact.
  • Hinge type cage connectors 120 at the top of the cage thus cooperate together with resilient sections 114 formed on the cage towards the sides and bottom of the cage so that the bottom of the cage recoils rearwardly with compression of the resilient sections 114 as the cage pivots about the hinge axis of the cage connectors 120 at the top of the cage.
  • the outer shell defines a goalie hockey helmet such that the outer shell fully surrounds the central viewing area aligned with the eyes and face of the user such that a portion of the outer shell provides coverage across the jaw area of the user.
  • a plurality of ventilation openings 122 are provided in the outer shell surrounded by solid and non-perforated connecting portions of the outer shell between the ventilation openings.
  • the material of the outer shell is formed into a plurality of structural members 124 interconnected with one another and spanning across the ventilation opening such that the ventilation opening is fully covered by the structural members 124 which collectively form a woven type mesh or an open lattice structure that provides numerous openings therethrough through which air can still be ventilated while providing a rigid structure resistant to impacts at the ventilation opening.
  • the structural members 124 provide a covering over each ventilation opening 122 and are formed by three- dimensional printing together with the remainder of the outer shell.
  • the outer shell 104 can also be formed with strap connectors 126 formed thereon which are suitable for attachment of various helmet straps mounted thereon.
  • the strap connectors 126 comprise male snap connectors which form a snap-fit connection with corresponding female snap connectors on the helmet straps.
  • the strap connectors comprise suitably sized slotted openings that receive straps threaded therethrough about the periphery of the outer shell.
  • the configuration of the strap connectors 126 are formed integrally with the remainder of the outer shell together as part of the three- dimensional printing process.
  • the outer shell may also be formed by three-dimensional printing to integrally include various accessory mounts 128 formed therein.
  • the accessory mounts can include integral hooks, or various shaped openings or eyelets that enable attachment of accessories such as a neck guard suspended from the outer shell.
  • other types of accessory mounts 128 include openings to receive various electronic hardware including cameras and the like.
  • the interior of the outer shell may also be configured with various cavities or pockets that serve to mount other electronic hardware therein including sensors or batteries and the like.
  • the helmet according to figure 8 also shows an example of three-dimensional shapes 129 representing various indicia being formed on the outer surface of the outer shell is part of the three-dimensional printed structure forming the outer shell.
  • the three-dimensional texture 129 may include debossed indicia, embossed indicia, or internal textured shapes that can be viewed from the exterior by the thinning of the material of the outer shell produce a visible logo in the manner of a lithophane for example.
  • the outer shell may be formed in multiple shell sections 130 which are interconnected to form the overall shape of the outer shell. As shown in figure 14, two adjacent shell sections 130 of the outer shell are joined to one another at peripheral edges such that each shell section defines a respective portion of the exterior boundary of the outer shell of the assembled helmet.
  • the edges of the shell sections are preferably formed with cooperating shapes 132 that interlock with one another in a suitable manner to define a hinge like structure where the shell sections can be pivoted or folded relative to one another. More particularly, in response to an external impact, the shell sections 130 can be pivoted relative to one another such that the junction between adjacent shell sections is deflected inwardly for compression of the resilient coupling or a compressible layer between the inner and outer shells.
  • the boundary edges of the shell sections may also be provided with stops 134 that engage with one another once the shell sections have pivoted or angularly deflected relative to one another by a prescribed amount, after which further relative deflection is prevented.
  • the stops 134 thus define a limited or prescribed range of angular deflection permitted by the interlocking shapes between the adjacent shell sections.
  • the relative movement between shell sections interlocked with one another serves to redirect impacts from one location at the exterior of the helmet to one of the junctions between adjacent shell sections representing an area less critical to injury or an area of the helmet where greater strength is provided by the resilient coupling or the inner shell.
  • the resilient coupling 106 may allow a variety of relative movement between the outer shell and the inner shell or may be directional to primarily direct relative movement between the outer shell and the inner shell along a prescribed axis such as a longitudinal axis extending between front and rear of the helmet.
  • the resilient coupling includes a plurality of first coupling elements 136 formed integrally with the outer shell by three- dimensional printing, and a plurality of second coupling elements 138 formed integrally with the inner shell by three-dimensional printing.
  • first elements 136 comprise protrusions or fingers which are elongated and flexible and which are formed at the distal ends to mate with the second elements which represent sockets receiving the protrusions or fingers therein.
  • the sockets may be sized and shaped to retain the distal ends of the protrusions therein by friction fit, or snap-fit arrangement, or with an arrangement of catches retained on respective shoulders or undercut surfaces on the protrusions and sockets respectively.
  • the protrusions or fingers defining the first elements 136 are shown generally aligned in a common direction with one another in the illustrated embodiment, however in other embodiments the elements may be oriented at various transverse directions relative to one another in which the direction that the fingers are sloped relative to one or both of the inner and outer shell can be used to dictate the direction of relative movement of the outer shell relative to the inner shell in response to an impact.
  • the sockets have a semispherical shape receiving the distal ends of the protrusions therein, providing sockets at opposing sides of the helmet which are oriented in opposing directions may be sufficient to retain the protrusions within the sockets to couple the outer shell relative to the inner shell.
  • the resilient coupling 106 as shown may be combined with other types of couplings of different configuration which serve to align the outer shell with the inner shell to suitably align the first elements 136 in mating and interlocking cooperation with the second elements 138.
  • the coupling elements may comprise a plurality of three-dimensional printed resilient elements 140 interconnected between the inner shell in the outer shell.
  • the resilient elements may be integrally formed with only one of the inner or outer shell while simply abutting the opposing shell, or may be formed integrally with both the inner and outer shell when the inner and outer shell and the resilient coupling are collectively three dimensionally printed as a single unitary structure.
  • the resilient elements may be formed as arches 140 A which can flex and collapse in response to an impact.
  • the resilient elements may comprise sinusoidal or helical springs 140B which are similarly resiliently deformed in response to an impact.
  • the resilient elements may comprise posts 140C with a line of weakness formed therein defining a fold line or hinge point about which the resilient element is resiliently folded to deflect and return to shape responsive to an impact.
  • the resilient coupling may again be defined by a plurality of first coupling elements 136 integrally formed with the outer shell and second elements 138 integrally formed with the inner shell.
  • the second elements again comprise sockets which receive the distal ends of the first elements formed as protrusions or fingers received in the sockets; however, the coupling elements in figure 13 are distinguished in that the first elements are rigid non-compressible elements which are instead coupled to the sockets of the second elements 138 to define a relative linear movement therebetween similar to a piston received within a cylinder.
  • the first and second elements thus define a relative linear motion which may be oriented in the radial direction normal to the inner and outer shells or in a transverse direction that is sloped relative to the shells and the normal direction.
  • the coupling element 106 in this instance further includes a resilient element 142 located in the chamber of the socket between the terminal end of the socket and the protrusion of the first element 136 such that an impact causes the first elements to be slidable into the sockets in a manner that compresses the resilient element 142 at each coupling.
  • the resilient element may be a compressible material such as a gel or fluid or a flowable fluid that is redirected into an expandable chamber.
  • the resilient element 142 may yet further comprise a resilient member such as a three-dimensional spring or deformable structure that is three dimensionally printed together with the socket.
  • some of the first and second coupling elements 136 and 138 may be oriented such that the linear sliding direction thereof is oriented transversely to other coupling elements.
  • each protruding piston or first coupling element 136 may be joined to the respective shell to allow for some relative pivotal movement, for example by a line of weakness defining a fold line or other suitable structures for forming a hinge.
  • the resilient coupling in this instance may be arranged to provide a stepped increase in resistance to a deflected movement of the outer shell relative to the inner shell in response to an increasing deflection of the outer shell relative to the inner shell. More particularly, the resilient coupling is arranged to provide a first resistance to the deflection until a first deflection amount is achieved at which point a second larger resistive force to the deflection is initiated. As deflection continues past a second deflection amount greater than the first deflection amount, a third larger resistive force to the deflection can be initiated.
  • the resilient coupling includes a plurality of first resilient elements 144, a plurality of second resilient elements 146 and a plurality of third resilient elements 148.
  • Each set of resilient elements, 144, 146 and 148 are actuated to provide resistive force against deflection at different amounts of deflection while also providing different resistive forces to the deflection.
  • the first resilient elements 144 in this instance span the greatest distance across the gap between the inner and outer shells such that the first elements 144 will immediately undergo resilient deformation and provide resistive force to the deflection as the outer shell is deflected up to a first deflection amount relative to the inner shell.
  • the remaining elements are shorter than the first elements 144 and do not engage the inner shell such that they do not undergo any deflection or provide any resistive force to the deflection until the first deflection amount is reached.
  • the shorter second elements 146 begin to engage the inner shell and undergo resilient deformation so as to provide much greater resistance to the deformation than the first elements alone.
  • the second elements may also be thicker than the first elements so that each individual second element divides greater resistance to deformation than the first elements.
  • the shortest third elements 148 that are shorter than both the first and second elements begin to engage the inner shell and undergo resilient deformation so as to provide an even greater resistance to the deformation than the first and second elements.
  • the third elements may also be thicker than both the first elements and the second element such that each individual third element provides greater resistance to the deformation than the first elements or the second elements individually.
  • yet further stages to resist deformation may be provided by further resilient elements engaging at a further deflection amount.
  • the liner 100 is preferably formed as a three-dimensional printed structure together with the shells or as a separate component to be coupled to the shells after manufacture.
  • the liner 100 and the inner shell 102 are preferably provided with releasable connectors as shown in figures 16 through 18 for example to releasably mount the liner 100 fixedly relative to the inner shell without additional mounting hardware or adhesives and the like being required.
  • a protruding connector 150 is provided on the inner shell to protrude into the interior for mating with a corresponding socket 152 formed integrally on the liner.
  • the protrusion 150 may instead be formed on the liner while the sockets may be formed on the inner shell.
  • the protrusion mates with the corresponding socket using a resilient catch 154 retained on a corresponding retaining surface in the socket.
  • the catches are provided on a pair of sprung arms 156 which are biased outwardly to engage the catches on the respective retaining surfaces. Pulling the releasable connectors apart with sufficient force causes the arms 156 to be resiliently deflected inwardly relative to one another to release the catches from the corresponding retaining surfaces.
  • the catches may be formed on diametrically opposed barbs extending outward from the protrusion for selective mating with retaining surfaces formed in the opposing boundary walls of the socket 152. Pulling the connectors apart causes the material of the protrusion or the socket to be resiliently compressed to sufficiently release the catches from the retaining surfaces.
  • the protrusion in this instance may comprise a mushroom head type connector with undercut surfaces at opposing sides thereof.
  • the catches in this instance are formed on resilient arms 158 so that the catches are biased to extend inwardly towards one another to be retained on the opposing undercut surfaces of the mushroom head.
  • the releasable connectors integrally formed on the liner 100 and the inner shell 102 may cooperate by friction fit or using hook and loop type fasteners integrally formed on the liner and the inner shell as part of the three-dimensional printing process.
  • the liner 100 received within the shells may be provided with one or more cavities formed integrally therein as part of the three-dimensional printing process such that the cavities may be recessed fully into the interior of the liner in spaced relation to either the interior or exterior boundaries of the liner.
  • the cavities may include strap cavities 160 in the form of elongate passages extending fully through the liner to receive respective helmet straps threaded therethrough which serve to strap the helmet onto the head of the user.
  • the cavities comprise hardware cavities 162 that are suitably arranged to receive various electronic hardware therein including camera components, impact sensors of various types for monitoring impacts, or batteries associated with any of the electronics for example.
  • the liner 100 may also be formed integrally by three-dimensional printing together with one or more lattice structures 164 which occupy any irregular shaped voids between the liner and the shell layers.
  • an aerodynamic bicycle helmet is illustrated in longitudinal cross-section in which the bike helmet is shown to include an inner shell 102 formed of a rigid foam material to be mounted against the head of the user possibly without an additional liner being required, and an outer shell 104 forming a smooth and continuous exterior boundary of the helmet which defines the aerodynamic shape of the helmet.
  • a large void defined between the inner protective shell 102 and the outer aerodynamic shell 104 in this instance is occupied by a three-dimensional printed lattice structure 166.
  • the lattice structure can be formed integrally of the same material and as a single manufacturing step together with either one of the inner shell 102 or the outer shell 104.
  • the lattice structure provides a resiliently deformable crumple zone about the inner shell 102 so as to again allow some resilient movement of the outer shell relative to the inner shell.
  • FIG. 10 another embodiment of the protective article 10 will now be described in further detail in which the article is again a sports helmet that is particularly suited for being worn by a goalie in the sport of hockey.
  • the helmet 10 again includes an inner shell 12 arranged to be worn against the head of the user, an outer shell 14 arranged to at least partly surround the inner shell on the head of the user, and a coupling arrangement between the inner shell 12 and the outer shell 14 which allows some resilient relative movement between the shells such that the outer shell can be deflected relative to the inner shell from a neutral position to a deflected position while being biased to return to the neutral position.
  • the coupling arrangement further allows one or more movements of the outer shell relative to the inner shell including translational movements, rotational movements having a centre of rotation inside the inner shell, and radial movements inward and outward relative to a centre of the generally spherical shape of the helmet.
  • the inner shell 12 is a rigid unitary body.
  • An additional layer of a resilient or compressible lining material may be mounted as a liner on an inner surface of the rigid body forming the inner shell.
  • the inner shell 12 is intended to be worn in a tightfitting manner about the face and part of the head of the user such that it may be desirable for the inner shell 12 to be manufactured in a plurality of different sizes and shapes to best fit the head of the user.
  • the inner shell may be custom fit or custom manufactured to match the shape of the head of the user.
  • the inner shell may be manufactured and subsequently moulded to the head of the user for example using thermoforming techniques to make the inner shell malleable under application of heat to take the shape of the head of the user followed by allowing the inner shell to cool to form a rigid moulded shape that closely fits the head of the user.
  • the inner shell may be custom manufactured using three-dimensional printing techniques according to printing instructions which have been modified to take into consideration custom measurements taken from the head of the user to ensure the printed structure of the inner shell closely fits the head of the user.
  • the inner shell 12 has a shape which approximately forms part of a sphere in shape while being sized to cover various parts of the head of the user. More particularly, the inner shell includes (i) a top section 16 for spanning the top of the head of the user, (ii) a pair of side sections 18 extending downwardly from opposing sides of the top section while remaining substantially above the ears of the user, (iii) temporal sections 20 extending forwardly from the side sections 18 to extend over temporal regions of the user and to extend downwardly in front of the ears below the bottom edges of the side sections 18, (iv) a forehead section 22 extending downwardly and forwardly from the front edge of the top section so as to be connected across the forehead of the user between the temporal sections 20, (v) two jaw sections 24 extending downwardly from the temporal regions 20 respectively along respective portions of the jaw of the user, and (vi) a central chin section 26 connected between the jaw sections 24 for partly engaging the chin of the user.
  • the forehead section 22, the temporal sections 20, the jaw sections 24, and the chin section 26 collectively extend about a full perimeter of a central opening 28 in the inner shell that aligns with the mouth, nose and eyes of the user.
  • the inner shell is otherwise continuous and uninterrupted across the width and height of the inner shell between opposing perimeter edges.
  • the inner shell 12 remains open at the rear and bottom by a rear bottom opening 30 receiving the head and the neck of the user inserted therethrough when mounting the inner shell onto the head of the user.
  • the helmet 10 further includes a rear shell 32 which is also formed as a rigid unitary body.
  • the rear shell 32 forms part of a sphere in shape and is sized to closely fit perimeter edges of the inner shell about the rear opening 30 at the rear of the top section 16 and the rear of the side sections 18.
  • the rear shell 32 may also be provided with a resilient or compressible lining on the inner surface thereof to comfortably fit the rear shell to the rear of the head of the user.
  • the rear shell 32 is coupled to the inner shell 12 by a set of straps of resilient or elastic material that are connected under tension between the rear shell and respective portions of the inner shell 12.
  • the straps include a plurality of upper straps 34 connected between the rear shell and respective mounting locations on the top section 16 and the side sections 18 of the inner shell at circumferentially spaced locations about the top and sides of the inner shell.
  • a set of lower straps 36 are connected at laterally opposing sides of the rear shell adjacent the bottom thereof to respective mounting locations on the jaw sections 24 of the inner shell respectively. In this manner, the lower straps 36 extend longitudinally forward from the rear shell to the inner shell at a location below the ears of the user.
  • the outer shell 14 is also provided as a single unitary body of rigid material.
  • the outer shell is generally sized and configured relative to the inner shell such that the outer shell can be mounted to fully cover and conceal the inner shell while remaining spaced radially outward from a centre of the helmet relative to the inner shell.
  • the outer shell 14 is formed to include (i) a top section 38 for covering the top section 16 of the inner shell, (ii) a forehead section 40 for covering the forehead section 22 of the inner shell, (iii) two side sections 42 extending downwardly from opposing sides of the top section 38 to fully cover the side sections 18 of the inner shell as well as extending further downward to fully span the ears and upper neck of the user at opposing sides of the head, and (vi) a lower section 44 which extends across the front of the helmet between the two side sections 42 of the outer shell to fully span over and conceal the jaw sections 24 and the chin section 26 of the inner shell.
  • the lower section 44 may also be tapered downwardly in front of the neck of the user in the same manner as a conventional hockey goalie mask.
  • a central area at a front of the mask includes a viewing portion 46 formed in the outer shell in the form of a central opening which is fully surrounded by the forehead section 40 above, the side sections 42 at laterally opposing sides thereof and the lower section 44 therebelow.
  • a set of bars 48 extend across the central opening and are interconnected with one another to define a cage extending across the central opening 46 to divide the central opening into smaller apertures of suitable dimension to prevent pucks penetrating through the apertures into the interior of the helmet.
  • the viewing portion 46 is aligned with the central opening 28 formed in the inner shell to provide full visibility to the user of the helmet.
  • the overall area of the viewing portion 46 is typically larger than the central opening 28 in the inner shell to maximize visibility through the outer shell despite the outer shell being positioned forwardly and outwardly from the inner shell 12 against the head of the user.
  • the rear edge of the top section 38 and the rear edges of the side section 42 are arranged to be positioned near or rearward from the rearmost portion of the rear shell 32 in a mounted position on the head of the user. More particularly, the top section 38 and the side sections 42 each protrude rearwardly farther than corresponding rear edges of the side sections 18 and top section 16 of the inner shell that form the strapped connection to the rear shell 32. In this manner, the upper and lower straps are concealed beneath the outer shell at the sides and top of the helmet.
  • the outer shell is oversized relative to the inner shell with a gap being provided between the inner shell and the outer shell in all directions to provide a clearance gap between the inner shell and outer shell that allows the outer shell to be deflected from a neutral position suspended over the inner shell in many different directions including the relative translational, rotational, and radial directions described above.
  • the coupling arrangement provides a connection between the top section 16 of the inner shell and the top section 38 of the outer shell as well as between the side sections 18 of the inner shell and the corresponding side sections 42 of the outer shell such that all of the connections of the coupling arrangement are located substantially above the level of the ears of the user and generally rearward of the temporal regions of the user.
  • the outer shell remains spaced radially outward from the inner shell along the forehead section 40, and along the entirety of the lower section 44 relative to the corresponding forehead section, jaw sections and chin section of the inner shell. Accordingly at the front side of the helmet, the outer shell is supported fully spaced outward from and separated by a clearance gap from the inner shell against the face or head of the user.
  • the coupling arrangement generally includes a plurality of tracks 50 which are mounted on an inner surface of the outer shell 14 and a plurality of corresponding followers 52 which are mounted to protrude from the outer surface of the inner shell 12.
  • One or more of the followers 52 is coupled in a mating connection with each track 50 such that the followers 52 are slidably movable along the respective tracks 50.
  • the tracks 50 all extend in a common longitudinal direction of a longitudinal axis extending from a central location at the rear of the helmet to a central location at the front of the helmet.
  • the longitudinal axis in which the tracks extend defines the translating movement of the outer shell relative to the inner shell as the followers are displaced longitudinally within the respective tracks 50 forwardly and rearwardly.
  • Each follower 52 is a pin having an enlarged head 54 which is reduced in diameter at the inner end forming a stem 56. Beneath laterally opposing sides of the enlarged head 54 where the dimension of the pin is stepped inwardly at opposing sides, two shoulder surfaces 58 are defined so that the follower is generally T-shaped.
  • Each track 50 includes a groove formed within protruding channel mounted on the inner surface of the outer shell.
  • the grooves of the tracks 50 generally T-shaped in profile to match the shape of the followers 52 received therein.
  • the internal groove defining each track thus includes a central main guideway 60 sized to receive the enlarged head 54 of each follower longitudinally slidable therein and two undercut surfaces 62 beneath laterally opposed flanges at the mouth of the groove.
  • the undercut surfaces 62 align with and engage the shoulder surfaces 58 of the followers received therein such that when the followers are mated within the respective tracks, the followers are restricted from removal in a radial direction while remaining freely slidable longitudinally along the length of the track.
  • Each follower 52 is radially compressible from a neutral position when the outer shell is spaced outwardly in a balanced manner form the inner shell, to a retracted position corresponding to the follower being radially compressed in length.
  • Each follower 52 is biased to return to the neutral position when deflected inwardly into the retracted position.
  • the follower 52 is retractable by forming the head 54 of each follower as a telescoping member with an internal spring mounted therein biasing the head to expand radially in dimension.
  • the head occupies the full depth of the groove in the corresponding track 50; however, a radially inward impact in the area of the follower causes the head 54 to be radially compressed which in turn allows the outer shell 14 to be deflected radially inwardly towards the inner shell 12.
  • the internal spring within the head 54 immediately biases the follower to return to the extended and neutral position, which in turn returns the outer shell to a neutral position relative to the inner shell 12.
  • each follower may be radially compressible or telescoping in nature to allow the outer shell to be similarly radially deflected inwardly relative to the inner shell followed by outward biasing to return the outer shell to the neutral position.
  • Each track 50 is also provided with a plurality of longitudinal springs 64 biasing each follower in the longitudinal direction to return to an intermediate neutral position corresponding to the neutral position of the outer shell relative to the inner shell.
  • the followers are generally located closer to the forward end of the tracks such that the outer shell can be deflected rearward relative to the inner shell from the neutral position by a greater distance than the outer shell can be deflected forwardly relative to the inner shell from the neutral position.
  • the longitudinal springs bias the followers back to their respective neutral positions which in turn re-positions the outer shell in the neutral position relative to the inner shell.
  • the overall combination of the longitudinal tracks extending generally rearward together with the ability of each follower to be compressed radially allows a combination of translational and radial movements to occur between the outer shell and the inner shell such that the resulting movement may be a rotational movement of the outer shell relative to the inner shell within a controlled range.
  • Controlling the force required to compress the followers in the radial direction as well as controlling the force required to deflect the outer shell rearwardly relative to the inner shell by translating movement of any of the followers within the tracks allows different degrees of absorption of forces to occur between the outer shell in the inner shell.
  • the outer shell 14 is fully formed as a single unitary body manufactured as a three-dimensional printed structure.
  • the single three-dimensional printed structure is formed of uniform material throughout which includes the top section 38, the forehead section 40, the side sections 42, the lower section 44, and the bars 48 extending across the viewing portion 46.
  • the singular body formed by the three- dimensional printed structure may also include the channels forming the tracks 50 integrally formed on the inner surface of the outer shell.
  • the majority of the outer shell forming the top section 38, the forehead section 40, the side sections 42 and the lower section 44 may be manufactured as a three-dimensional lattice of individual struts connected at respective nodes so as to be oriented relative to one another in three dimensions.
  • the three-dimensional printed structure is preferably formed of metal which is printed as an open framed lattice that remains open and porous to allow ventilation through the shell.
  • the printed lattice structure is strong and lightweight, while the lattice can be printed in different densities at different regions of the helmet to ensure the outer shell is either fully rigid or has a controlled degree of resilience and shock absorption at specific regions.
  • the outer shell can be formed of various composite materials, fiberglass, plastic materials, or any combination thereof while still be supported for resilient movement relative to the inner shell as described above.

Landscapes

  • Helmets And Other Head Coverings (AREA)

Abstract

La présente invention concerne un article de protection, tel qu'un casque, comprenant une coque interne dotée d'une doublure optionnelle portée sur l'utilisateur et une coque externe montée au-dessus de la coque interne par un couplage élastique qui permet un mouvement élastique de la coque externe par rapport à la coque interne en réponse à des impacts. Le couplage élastique est formé par impression tridimensionnelle d'un seul tenant avec une ou les deux coques. D'autres éléments comprenant des éléments de fixation de sangle, des éléments de protection sur des ouvertures de ventilation, des supports de cage et similaires peuvent également être imprimés d'un seul tenant avec la ou les coques. Une cage est disposée séparément ou d'un seul tenant avec la coque externe dans laquelle la cage est formée par impression pour définir des barres d'intersection qui peuvent varier en forme, en taille ou en orientation angulaire ou définir un profil de faisceau ayant des caractéristiques directionnelles variables le long de sa longueur. Un couplage élastique entre la cage et le casque peut également être imprimé d'un seul tenant avec la ou les cages.
PCT/CA2024/051050 2023-08-11 2024-08-09 Casque de protection doté d'une cage optionnelle WO2025035207A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202363518973P 2023-08-11 2023-08-11
US63/518,973 2023-08-11

Publications (1)

Publication Number Publication Date
WO2025035207A1 true WO2025035207A1 (fr) 2025-02-20

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ID=94631918

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PCT/CA2024/051050 WO2025035207A1 (fr) 2023-08-11 2024-08-09 Casque de protection doté d'une cage optionnelle

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Country Link
WO (1) WO2025035207A1 (fr)

Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5101517A (en) * 1990-07-06 1992-04-07 Willie Douglas Sports helmet with transparent windows in the side walls
DE29621145U1 (de) * 1996-12-05 1997-01-23 Schöllhorn, Andreas, Dipl.-Ing. (FH), 85464 Finsing Schutzhelm zum Klettern in künstlichen Kletteranlagen
DE202004012285U1 (de) * 2004-08-02 2004-09-30 Hegendörfer, Erich Schutzhelm
EP3000341A1 (fr) * 2014-09-25 2016-03-30 Stefan Züll Casque de protection
US20160369861A1 (en) * 2011-09-08 2016-12-22 Emerson Spalding Phipps Protective member
US20180160760A1 (en) * 2012-03-06 2018-06-14 Loubert S. Suddaby Protective helmet with energy storage mechanism
US20190133235A1 (en) * 2017-09-28 2019-05-09 Noggin Locker, Llc Shock Reducing Helmet
US20190231018A1 (en) * 2016-10-17 2019-08-01 Syncro Innovation Inc. Helmet, process for designing and manufacturing a helmet and helmet manufactured therefrom
US20210161241A1 (en) * 2013-05-01 2021-06-03 F3 Tech, Llc Mask
US20220022586A1 (en) * 2018-09-20 2022-01-27 Mips Ab Helmet

Patent Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5101517A (en) * 1990-07-06 1992-04-07 Willie Douglas Sports helmet with transparent windows in the side walls
DE29621145U1 (de) * 1996-12-05 1997-01-23 Schöllhorn, Andreas, Dipl.-Ing. (FH), 85464 Finsing Schutzhelm zum Klettern in künstlichen Kletteranlagen
DE202004012285U1 (de) * 2004-08-02 2004-09-30 Hegendörfer, Erich Schutzhelm
US20160369861A1 (en) * 2011-09-08 2016-12-22 Emerson Spalding Phipps Protective member
US20180160760A1 (en) * 2012-03-06 2018-06-14 Loubert S. Suddaby Protective helmet with energy storage mechanism
US20210161241A1 (en) * 2013-05-01 2021-06-03 F3 Tech, Llc Mask
EP3000341A1 (fr) * 2014-09-25 2016-03-30 Stefan Züll Casque de protection
US20190231018A1 (en) * 2016-10-17 2019-08-01 Syncro Innovation Inc. Helmet, process for designing and manufacturing a helmet and helmet manufactured therefrom
US20190133235A1 (en) * 2017-09-28 2019-05-09 Noggin Locker, Llc Shock Reducing Helmet
US20220022586A1 (en) * 2018-09-20 2022-01-27 Mips Ab Helmet

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