Search

US-12622480-B2 - Helmet with custom-fit liner

US12622480B2US 12622480 B2US12622480 B2US 12622480B2US-12622480-B2

Abstract

A sports helmet kit has a shell, attachable face guard, composite helmet liner, and fit pods to improve and customize the fit of the helmet to the wearer. The composite liner consists of a base liner and a selected group of fit elements, for example, fit pods, removably attached to the inner surface of the base liner (i.e., the surface of the base liner facing the wearer's head). The fit pods are selected from a set of fit pods having different properties, for example, different sizes, thicknesses, densities, and cross-sections. The selection of fit pods from the set may be aided by taking anatomical measurements of the wearer's head and analyzing the measurements with respect to the geometry of the helmet to produce a pressure map. The measurements may be taken by physical contact or by non-contact means. The fit pods may be selected to optimize a pressure map, and thus optimize the fit, for a given wearer of the helmet.

Inventors

  • Louis Anthony VanHoutin
  • Vincent R. Long
  • Nathan LOUCKS
  • Richard GROFF, III

Assignees

  • SCHUTT SPORTS IP, LLC

Dates

Publication Date
20260512
Application Date
20250303

Claims (20)

  1. 1 . A helmet kit comprising: a helmet shell adapted to protect a head of a wearer, the helmet shell including a first internal area and a second internal area that are spaced apart therein; an internal padding structure comprising a first liner pad and a second liner pad, the first liner pad configured to layer over the first internal area and the second liner pad configured to layer over the second internal area, the first liner pad including a first surface with a first demarcation corresponding to a first pod site facing the head of the wearer when disposed within the helmet shell, the second liner pad including a second surface with a second demarcation corresponding to a second pod site facing the head of the wearer when disposed within the helmet shell, wherein at least one of the first demarcation and the second demarcation is an alphanumeric symbol; and a plurality of fit pods including a first fit pod and a second fit pod removably attachable within the helmet shell with the internal padding structure layered between the helmet shell and the plurality of fit pods, the first fit pod layered upon the first pod site and the second fit pod layered upon the second pod site in a customized fit configuration.
  2. 2 . The helmet kit of claim 1 , wherein at least one of the first internal area and the second internal area defines a lateral area of the helmet shell configured to cover a lateral portion of the head of the wearer.
  3. 3 . The helmet kit of claim 1 , wherein at least one of the first demarcation and the second demarcation comprises a line extending along the respective one of the first surface and the second surface.
  4. 4 . The helmet kit of claim 3 , wherein the line is inscribed in the respective one of the first surface and the second surface.
  5. 5 . The helmet kit of claim 1 , wherein the first liner pad comprises thermoplastic urethane (TPU) material.
  6. 6 . The helmet kit of claim 5 , wherein the first fit pod comprises a vinyl material.
  7. 7 . The helmet kit of claim 1 , wherein the internal padding structure is removably attached within the helmet shell and customizable according to the head of the wearer.
  8. 8 . The helmet kit of claim 1 , wherein the first fit pod is one of a plurality of first fit pods arranged in a first set, the plurality of first fit pods being interchangeable for the helmet kit, and wherein the first fit pod is chosen from the first set for providing the customized fit configuration.
  9. 9 . The helmet kit of claim 1 , wherein the first liner pad includes a bottom sheet and a top sheet that is attached to the bottom sheet to cooperatively define a cell therebetween, the first liner pad including a liner pad that is received within the cell.
  10. 10 . A helmet kit comprising: a helmet shell adapted to protect a head of a wearer, the helmet shell including a first internal area and a second internal area that are spaced apart therein; an internal padding structure comprising a first liner pad and a second liner pad, wherein the internal padding structure is removably attached within the helmet shell and customizable according to the head of the wearer, the first liner pad configured to layer over the first internal area and the second liner pad configured to layer over the second internal area, the first liner pad including a first surface with a first demarcation corresponding to a first pod site facing the head of the wearer when disposed within the helmet shell, the second liner pad including a second surface with a second demarcation corresponding to a second pod site facing the head of the wearer when disposed within the helmet shell; and a plurality of fit pods including a first fit pod and a second fit pod removably attachable within the helmet shell with the internal padding structure layered between the helmet shell and the plurality of fit pods, the first fit pod layered upon the first pod site and the second fit pod layered upon the second pod site in a customized fit configuration.
  11. 11 . The helmet kit of claim 10 , wherein at least one of the first liner pad and the second liner pad includes an inflatable structure, the inflatable structure having an adjustable internal pressure for customizing fit of the helmet kit to the head of the wearer.
  12. 12 . The helmet kit of claim 10 , wherein the first fit pod is one of a plurality of first fit pods arranged in a first set, the plurality of first fit pods being interchangeable for the helmet kit, and wherein the first fit pod is chosen from the first set for providing the customized fit configuration.
  13. 13 . The helmet kit of claim 12 , wherein individual ones of the plurality of first fit pods differ in at least one characteristic chosen from a group consisting of: height, width, shape, size, cross-section, material, thickness, stiffness, firmness, density and hardness.
  14. 14 . The helmet kit of claim 10 , wherein the first liner pad includes a bottom sheet and a top sheet that is attached to the bottom sheet to cooperatively define a cell therebetween, the first liner pad including a liner pad that is received within the cell.
  15. 15 . A helmet kit comprising: a helmet shell adapted to protect a head of a wearer, the helmet shell including a first internal area and a second internal area that are spaced apart therein; a helmet liner system adapted for providing a customized fit configuration according to the head of the wearer, the helmet liner system comprising: an internal padding structure comprising a first liner pad and a second liner pad, wherein the internal padding structure is removably attached within the helmet shell and customizable according to the head of the wearer, the first liner pad configured to layer over the first internal area and the second liner pad configured to layer over the second internal area, the first liner pad including a first surface with a first demarcation corresponding to a first pod site facing the head of the wearer when disposed within the helmet shell, the second liner pad including a second surface with a second demarcation corresponding to a second pod site facing the head of the wearer when disposed within the helmet shell; and a plurality of fit pods including a first fit pod and a second fit pod removably attachable within the helmet shell with the internal padding structure layered between the helmet shell and the plurality of fit pods, the first fit pod layered upon the first pod site and the second fit pod layered upon the second pod site in the customized fit configuration.
  16. 16 . The helmet kit of claim 15 , wherein at least one of the first internal area and the second internal area defines a lateral area of the helmet shell configured to cover a lateral portion of the head of the wearer.
  17. 17 . The helmet kit of claim 15 , wherein the first liner pad includes a bottom sheet and a top sheet that is attached to the bottom sheet to cooperatively define a cell therebetween, the first liner pad including a liner pad that is received within the cell.
  18. 18 . The helmet kit of claim 15 , wherein at least one of the first demarcation and the second demarcation comprises a line inscribed into the respective one of the first surface and the second surface.
  19. 19 . The helmet kit of claim 15 , wherein at least one of the first liner pad and the second liner pad includes an inflatable structure, the inflatable structure having an adjustable internal pressure for customizing fit of the helmet kit to the head of the wearer.
  20. 20 . The helmet kit of claim 15 , wherein the first fit pod is one of a plurality of first fit pods arranged in a first set, the plurality of first fit pods being interchangeable for the helmet kit, and wherein the first fit pod is chosen from the first set for providing the customized fit configuration.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation of U.S. patent application Ser. No. 18/648,229, filed on Apr. 26, 2024; which is a continuation of U.S. patent application Ser. No. 17/340,907, filed on Jun. 7, 2021; which is a continuation of U.S. patent application Ser. No. 16/815,861, filed on Mar. 11, 2020, and issued on Jun. 8, 2021 as U.S. Pat. No. 11,026,466; which claims priority from U.S. provisional patent application No. 62/836,923, filed Apr. 22, 2019. The entirety of the related applications listed above are incorporated herein by reference for all purposes. STATEMENT REGARDING PRIOR DISCLOSURES BY THE INVENTORS OR JOINT INVENTORS UNDER 37 C.F.R. 1.77(b)(6) Less than one year before the filing date of U.S. Provisional Patent Application Ser. No. 62/836,923, commercial availability of a football helmet under the name Schutt F7 UR1 was announced by the applicant/assignee Schutt Sports. The applicant/assignee obtained the Schutt F7 UR1 football helmet directly or indirectly from the inventors of the present application. The Schutt F7 UR1 football helmet is an “inventor-originated disclosure” within the exceptions defined in 35 U.S.C. 102(b)(1). BACKGROUND OF THE SUBJECT TECHNOLOGY The subject technology concerns football helmets, which are worn to protect the head of a football player from impacts sustained during play. Modern football helmets generally comprise a plastic shell; internal padding inside the shell, attached directly or indirectly to the inner surface of the shell by, for example, T-nuts or hook-and-loop tape; and a face guard (i.e., a facemask) attached to the shell. Wearers of football helmets have differently shaped and sized heads, and different preferences for how their helmets should fit, therefore it is necessary to provide technology for fitting helmets to many different wearers. Football helmet shells are rigid articles of manufacture made by a molding process, and a manufacturer of football helmets may have a limited number of molds of different sizes of a given style of helmet. It is common for a manufacturer to offer a style of football helmet in a limited range of helmet shell sizes, from “small” to “extra-large,” for example, each size requiring a different mold. The needs of helmet wearers require more customization than can be afforded by a limited range of shell sizes. This is addressed by the structure of the internal padding. There is a need for internal padding configurations adapted to fit helmet wearers having many different requirements. Additionally, to be usable for competitive sports play, a helmet must meet certain standards. In the United States, the National Operating Committee on Standards for Athletic Equipment (“NOCSAE”) develops performance standards for protective equipment used in a variety of sports, including football helmets and faceguards. Generally, new football helmets and face guards must meet NOCSAE standards, and must be certified as such, to be marketable and usable in competitive football play in at least the collegiate varsity and professional levels. As used herein, “NOCSAE Standards” shall mean the effective NOCSAE standards applicable to football helmets and faceguards as amended. Although NOCSAE sets performance and test standards for athletic equipment, NOCSAE itself does not certify or approve athletic equipment. At the present time, NOCSAE requires third-party certification of compliance with its standards by a neutral, independent body. Currently, Safety Equipment Institute (SEI) oversees the certification of athletic equipment to NOCSAE standards. Equipment including football helmets that is certified to meet NOCSAE standards may be labeled or stamped with the appropriate certification mark, such as “Meets NOCSAE Standards” or “SEI Certified” or the like. As used herein, “NOCSAE-certified” shall mean equipment that is certified to meet NOCSAE's requirements for football helmets or faceguards as applicable, and which may or may not bear a NOCSAE certification mark. NOCSAE-certified equipment is deemed to meet NOCSAE Standards, as those terms are used herein. SUMMARY OF THE SUBJECT TECHNOLOGY According to a non-limiting embodiment of the subject technology, a helmet is provided with a composite helmet liner to improve and customize the fit of the helmet to the wearer. The composite liner consists of a base liner and a selected group of fit elements, for example, fit pods, removably attached to the inner surface of the base liner (i.e., the surface of the base liner facing the wearer's head). The fit pods are selected from a set of fit pods having different properties, for example, different sizes, thicknesses, densities, and cross-sections. The selection of fit pods from the set may be aided by taking anatomical measurements of the wearer's head and analyzing the measurements with respect to the geometry of the helmet to produce a pressure map. The measurements may be taken by physical contact or by non-co