Custom-fitted helmet and method of making the same

Abstract

A helmet liner that is custom-fitted to a wearer's head, and methods of making the liner, are provided. To make the liner, scanning equipment directly scans the person's head to generate computer-readable data containing a surface map of the head. This data then is used by suitable machining equipment to machine a custom-fitted liner from a universal liner blank, whose resulting convex surface will substantially conform to the shape and contour of the person's head. The scanning equipment desirably is or includes one or a plurality of lasers. A mobile platform including both the scanning and the machining equipment also is provided.

1 . A method of making an energy-absorbing liner that is custom-fitted to a wearer's head comprising: 
 a) directly scanning a person's head and generating computer-readable data comprising a surface map of the person's head;    b) providing a pre-made energy-absorbing liner blank having at least one surface; and    c) machining said at least one surface of said energy-absorbing liner blank, based on said computer-readable data, to provide a convex surface therein whose shape and contour substantially conform to the shape and contour of the person's head.    
   
   
       2 . A method according to  claim 1 , said impact energy-absorbing liner blank comprising viscoelastic foam.  
   
   
       3 . A method according to  claim 1 , said impact energy-absorbing liner blank comprising expanded polystyrene.  
   
   
       4 . A method according to  claim 1 , said impact energy-absorbing liner blank comprising expanded polypropylene.  
   
   
       5 . A method according to  claim 1 , further comprising providing an elastic cap over said person's head prior to scanning the head.  
   
   
       6 . A method according to  claim 1 , said energy-absorbing liner blank being made by molding a foaming composition in a mold, and curing said foaming composition to provide said energy-absorbing liner blank, said liner blank thereby being a foam liner blank.  
   
   
       7 . A method according to  claim 6 , said energy-absorbing foam liner blank comprising viscoelastic foam.  
   
   
       8 . A method according to  claim 6 , said energy-absorbing foam liner blank comprising expanded polystyrene.  
   
   
       9 . A method according to  claim 6 , said energy-absorbing foam liner blank comprising expanded polypropylene.  
   
   
       10 . A method according to  claim 6 , said foaming composition comprising isocyanate and at least one polyol.  
   
   
       11 . A method according to  claim 1 , said person's head being scanned by one or a plurality of lasers to generate said computer-readable data comprising a surface map of said person's head.  
   
   
       12 . A method according to  claim 11 , wherein a first scanning laser is oriented at an angle of 45° to the person's spine from above said person's head.  
   
   
       13 . A method according to  claim 12 , wherein a second scanning laser is oriented either at an angle of 90° to the person's spine or parallel to the person's spine.  
   
   
       14 . A method according to  claim 11 , wherein a first scanning laser is oriented at an angle of 90° to the person's spine and a second scanning laser is oriented parallel to the person's spine.  
   
   
       15 . A method according to  claim 1 , further comprising providing said impact energy-absorbing liner in a motorcycle helmet.  
   
   
       16 . A method according to  claim 1 , further comprising manipulating said computer-readable data to increase an effective radius along at least a portion of the surface map of said person's head in order to provide a predetermined clearance to accommodate the installation of comfort fitting foam into a helmet adjacent a finished energy-absorbing liner made from said liner blank.  
   
   
       17 . A method according to  claim 1 , said energy-absorbing liner blank being machined using CNC machinery, based on said computer-readable data, to provide a finished energy-absorbing liner having said convex surface therein whose shape and contour substantially conform to the shape and contour of said person's head.  
   
   
       18 . A method according to  claim 17 , said CNC machinery comprising a CNC router.  
   
   
       19 . A method according to  claim 1 , said computer-readable data being generated by scanning said person's head using a scanner or a coordinate measuring machine capable of directly scanning the head to measure the surface dimensions and contour thereof.  
   
   
       20 . A helmet that is custom-fitted to a particular wearer's head, the helmet comprising an impact energy-absorbing liner made according to the method of  claim 1 .  
   
   
       21 . A helmet that is custom-fitted to a particular wearer's head, the helmet comprising an impact energy-absorbing liner made according to the method of  claim 11 .  
   
   
       22 . A helmet according to  claim 21 , said energy-absorbing liner comprising viscoelastic foam.  
   
   
       23 . A helmet according to  claim 21 , said energy-absorbing liner comprising semi-rigid viscoelastic foam.  
   
   
       24 . A helmet according to  claim 21 , said energy-absorbing liner comprising expanded polystyrene.  
   
   
       25 . A helmet according to  claim 23 , said foam exhibiting substantially 100% crush recovery following an impact.  
   
   
       26 . An apparatus for producing a custom-fitted energy-absorbing liner, comprising means for directly scanning a person's head to generate computer-readable data comprising a surface map of said person's head, and means to machine an impact energy-absorbing liner blank to provide a convex surface therein whose shape and contour substantially conform to the shape and contour of said person's head, both said scanning means and said machining means being provided on a mobile platform.  
   
   
       27 . A combination according to  claim 26 , said mobile platform being a trailer or a truck.