Impact Absorbing Frame and Layered Structure System for Safety Helmets

Abstract

To be embedded within most customizable strong yet flexible safety helmet shells, is a strong, lightweight, impact absorbing “Frame” and a multi-layered impact absorbing cushioning “structure”. Two combined yet independent components designed to protect the user's head and cranium and to reduce the violent sudden acceleration and deceleration of the head and brain after impact. One aspect consists of a solid, continuous and unbroken “Frame” The frame comprises a number of semi-circular arched segments or “panels” with several other smaller semi-circular arched panels placed facing opposite the larger panels within the frame. The additional cushioning in the structure comprises several layers and levels of cushioning protection. These layers consist of a cushioning interior impact liner, a soft silicone gel material, a form fitting inner liner, and optional cloth liners.

1 . A protective headgear system to be embedded within most safety helmet shells. Incorporated within said customizable, strong yet flexible helmet shell is a strong, lightweight and impact absorbing “Frame” herein referred to as “frame” and a multi-layered impact absorbing cushioning “structure” herein referred to as “structure”. Said assembly herein collectively referred to as “system” or “Impact Absorbing Frame and Layered Structure System for Safety Helmets.” The system may be manufactured as an integrated, standalone protective layer that could be universally adapted and incorporated onto any modifiable safety helmet shell design shaped to correspond with the system and the user's head. Two combined yet independent components designed to protect the user's head and cranium and to reduce the violent sudden acceleration and deceleration of the head and brain after impact. 
   
   
       2 . The invention according to  claim 0001  wherein any strong yet flexible helmet shell would be the first protective layer. The outer shell of the helmet can be contoured to fit the parameters of the subsequent frame and layered structure. 
   
   
       3 . The invention according to  claim 0002  wherein the outermost layer or “outer shell” can be made up of a strong yet flexible construction preferably of fiber-reinforced composites or thermoplastics or the like with the unique quality of minimal sliding friction. 
   
   
       4 . The invention according to  claim 0001  wherein one component consists of a solid, continuous and unbroken “Frame” 
   
   
       5 . The invention according to  claim 0004  wherein the frame comprises a plurality of semi-circular arched segments or “panels” which are shaped to extend over and about the skull. 
   
   
       6 . The invention according to  claim 0005  wherein the semi-circular arched design of the panels within the frame allows them to dissipate and absorb impact forces due to their capability of spanning a space while supporting significant weight. 
   
   
       7 . The invention according to  claim 0004  wherein the frame is preferably made of lightweight and flexible yet strong and durable material made of fiber-reinforced composites or thermoplastics or the like. 
   
   
       8 . The invention according to  claim 0004  wherein there is a horizontal front panel which extends about the Frontal region of the skull. 
   
   
       9 . The invention according to  claim 0004  wherein there is a horizontal base panel which extends horizontally about the Frontal Base region of the skull. 
   
   
       10 . The invention according to  claim 0004  wherein there are two vertical base panels which extend vertically about the Frontal Base region of the skull. 
   
   
       11 . The invention according to  claim 0004  wherein there is a horizontal rear panel which extends horizontally about the Occipital region of the skull. 
   
   
       12 . The invention according to  claim 0004  wherein there are two vertical rear panels which extend vertically about the Occipital region of the skull. 
   
   
       13 . The invention according to  claim 0004  wherein two semi-circular arched top panels extend about the Parietal region of the skull. 
   
   
       14 . The invention according to  claim 0004  wherein there is a vertical cross-panel which extends about the Temporal and Parietal regions of the skull. 
   
   
       15 . The invention according to  claim 0004  wherein there is a curved mid-segment which extends throughout the Base region of the skull. 
   
   
       16 . The invention according to  claim 0004  wherein there is a plurality of inner opposite-facing arched panels. 
   
   
       17 . The invention according to  claim 0016  wherein said several smaller semi-circular arched segments being of approximately but not limited to equal degrees of curvatures are placed facing opposite the larger segments within the frame. 
   
   
       18 . The invention according to  claim 0016  wherein these arches are firmly coupled together at each end to the main unbroken part of the frame. 
   
   
       19 . The invention according to  claim 0018  wherein in a preferred embodiment, the ends of the inner opposite-facing arched panels are attached by way of tight fitting clamps or by other suitable means of attachment that would provide a firm hold yet allow the arches the freedom of movement to compress and expand. 
   
   
       20 . The invention according to  claim 0004  wherein the panels are spaced apart to provide for ventilation, with spacing between them of approximately but not limited to one inch or more. Thus, adequate ventilation is provided to dissipate heat and achieve a reasonable level of comfort while protecting the wearer. 
   
   
       21 . The invention according to  claim 0004  wherein the width of a panel is to be approximately but not limited to three quarters of one inch. 
   
   
       22 . The invention according to  claim 0004  wherein there is a cross-sectional thickness selected to provide the desired degree of impact protection 
   
   
       23 . The invention according to  claim 0004  wherein The panels are preferably single-layered, having one layer of approximately but not limited to one-eighth of one inch of density. 
   
   
       24 . The invention according to  claim 0004  wherein in a preferred embodiment, said frame is to be made continuous and unbroken with the exception of the inner opposite-facing arched panels. 
   
   
       25 . The invention according to  claim 0004  wherein also in a preferred embodiment, the frame is to be symmetrical from all sides. 
   
   
       26 . The invention according to  claim 0004  wherein Providing rigid protection under most circumstances, but upon impact the panels move relative to one another around the user's head and helmet compressing and expanding depending on the severity of the impact forces thereby permitting impact forces to be dissipated and/or redirected away from the cranium and brain within. 
   
   
       27 . The invention according to  claim 0001  wherein the additional layers in the structure comprises several levels of cushioning protection. 
   
   
       28 . The invention according to  claim 0027  wherein said layers would encase the “frame” so as not to come in contact with the user's head or helmet. 
   
   
       29 . The invention according to  claim 0027  wherein subsequent layers consist of a commercially available soft silicone gel material or the like, whose elasticity will allow for shock absorption, gently dispersing energy. 
   
   
       30 . The invention according to  claim 0028  wherein said layer would encase the entirety of the inner and outer portions of the frame, with exclusion to any sections designated for ventilation and/or visibility. 
   
   
       31 . The invention according to  claim 0028  wherein said layer would also encase the entirety of the inner and outer portions of the inner opposite-facing arched panels. 
   
   
       32 . The invention according to  claim 0027  wherein further subsequent layers are comprised of several levels of impact absorbing polymer material. These layers consist of a cushioning, impact absorbing material of a commercially available polymer structure such as polystyrene or polypropylene or the like, which further absorbs the impact energy and reduces the generated shockwave and simultaneously lowers the deceleration rate of the user's head. 
   
   
       33 . The invention according to  claim 0031  wherein said layer would encase the entirety of the inside of the helmet shell as well as the outer regions of the frame, with exclusion to any sections designated for ventilation and/or visibility. 
   
   
       34 . The invention according to  claim 0027  wherein the subsequent and last layer designated for contact with the head of a user may consist of a form fitting inner liner. 
   
   
       35 . The invention according to  claim 0034  wherein said liner is preferably made of a polymer material such as a commercially available foam material or the like, or a synthetic rubber polymer or the like. 
   
   
       36 . The invention according to  claim 0034  wherein in a preferred embodiment, said layer may contain optional detachable pads made of the same polymer material, a soft durable foam or the like that can be strategically placed inside the helmet by the wearer to accommodate different head shapes and sizes. 
   
   
       37 . The invention according to  claim 0027  wherein optional detachable inner liners to be worn for contact with the head of a user made of commercially available soft flexible cloth or the like may also be used. 
   
   
       38 . The invention according to  claim 0037  wherein in a preferred embodiment said liner may be made of commercially available soft flexible cloth or the like. 
   
   
       39 . The invention according to  claim 0037  wherein alternatively, a fire-retardant material or the like for contact with the head of a user may also be used. 
   
   
       40 . The invention according to  claim 0027  wherein each layer has a different density than the other layers. 
   
   
       41 . The invention according to  claim 0027  wherein in a preferred embodiment, the outermost layer farthest from the skull has the highest density to deflect impact forces and retain shape, while the subsequent inner layer has a lower density to absorb impact forces to minimize transmission of these forces through the helmet. Accordingly, the next and subsequent layer preferably has a lower density than the preceding layer. Finally the inner most layer has the lowest density so that it is pliable enough to conform to a users head. 
   
   
       42 . The invention according to  claim 0041  wherein while preferably, the layered structure may have a plurality of recurrent layers, other density/layer arrangements, additions and/or omissions are also useful. 
   
   
       43 . The invention according to  claim 0027  wherein there is a cross-sectional thickness selected to provide the desired degree of impact protection 
   
   
       44 . The invention according to  claim 0043  wherein said layers are preferably of approximately but not limited to one-eighth of one inch of density. 
   
   
       45 . The invention according to  claim 0027  wherein in a preferred embodiment, said layers are bonded or held together by way of commercially available processes. 
   
   
       46 . The invention according to  claim 0045  wherein said processes may include but are not limited to applying commercially available adhesive compounds, fabric hook-and-loop fasteners and/or commercially available stitching processes. 
   
   
       47 . The invention according to  claim 0031  wherein in a preferred embodiment of the invention, the layers are made of polystyrene or polypropylene, the aforementioned may be used in conjunction with other polymers and plastics to form the segments of the present invention. In addition to polystyrene or polypropylene, the segments may be made from, without limitation, a polybutylene, a polyvinyl (including polyvinyl chloride), a polyester, a polycarbonate, a polyurethane, a polyamine, a polyacrylic, a polyamide, a polyurea, and any other suitable polymer. 
   
   
       48 . The invention according to  claim 0028  wherein in a preferred embodiment of the invention, said layers are made of soft silicone gel material or the like, the aforementioned may be used in conjunction with other polymers and plastics to form the segments, said layers may be made with any other suitable polymer. 
   
   
       49 . The invention according to  claim 0001  wherein the frame and helmet shell are preferably made of lightweight and flexible yet strong and durable material made of fiber-reinforced composites or thermoplastics or the like, the aforementioned may be used in conjunction with other suitable composites and thermoplastics or any other suitable polymer to form the segments of the present invention.