Helmet with custom foam liner and removable / replaceable layers of crushable energy absorption material

Abstract

Multi-layered helmets deformably absorb an impact to a wearer that are provided with a rigid outer shell, a plurality of collapsible members configured to be permanently deformable to absorb energy in response to an applied force, and a flexible inner liner. The collapsible members are individually attachable to and removable from the inner surface of the rigid outer shell and to the flexible inner liner in a manner allowing individual replacement of a collapsible member upon being permanently deformed. The inside of the flexible inner liner is configured to face the head of a wearer.

What is claimed is: 
     
         1 . A multi-layered helmet for deformably absorbing an impact to a wearer, the multi-layered helmet comprising:
 a rigid outer shell having an inner surface;   a plurality of collapsible members, the collapsible members permanently deformable in response to an applied force, the deformation absorbing impact energy from the applied force, the plurality of collapsible members being individually attachable to and removable from the inner surface of the rigid outer shell, wherein the plurality of collapsible members are individually replaceable upon being permanently deformed;   a flexible inner liner having an outer surface and an inner surface, the plurality of collapsible members being individually attachable to and removable from the outer surface of the flexible inner liner, the inner surface of the flexible inner liner being configured to rest against the heard of a wearer.   
     
     
         2 . The multi-layered helmet of  claim 1 , further comprising:
 a plurality of voids formed at least in part by spaces between the plurality of collapsible members;   wherein the flexible inner liner comprises extension portions extending toward the rigid outer shell and fitting within the plurality of voids.   
     
     
         3 . The multi-layered helmet of  claim 1 , wherein the permanent deformation of at least one of the plurality of collapsible members is a breakage or a snapping of the least one of the plurality of collapsible members. 
     
     
         4 . The multi-layered helmet of  claim 1 , wherein at least one of the plurality of collapsible members is permanently deformed by a crushing or a folding of the at least one of the plurality of collapsible members. 
     
     
         5 . The multi-layered helmet of  claim 1 , wherein the plurality of collapsible members are removably attachable to the rigid outer shell and the flexible inner liner by hook and loop fasteners covering at least a portion of the inner surface of the rigid outer shell, the plurality of collapsible members, and the outer surface of the flexible inner liner. 
     
     
         6 . The multi-layered helmet of  claim 5 , wherein a first portion of the hook and loop fasteners removably attaches at least one of the plurality of collapsible members to the rigid outer shell and a second portion of the hook and loop fasteners removably attaches the at least one of the plurality of collapsible members to the flexible inner liner, the first and second portions having different attachment strengths. 
     
     
         7 . The multi-layered helmet of  claim 1 , wherein the plurality of collapsible members are removably attachable to the rigid outer shell and the flexible inner liner by a plurality of snap-fit connectors extending between the rigid outer shell, the plurality of collapsible members, and/or the flexible inner liner. 
     
     
         8 . The multi-layered helmet of  claim 7 , wherein the plurality of snap-fit connectors are pins having a shear breakage section configured to break in response to an applied shear force, the shear breakage section being positioned to be subjected to an applied shear force when the plurality of collapsible members translate relative to the rigid outer shell or the flexible inner liner. 
     
     
         9 . The multi-layered helmet of  claim 8 , wherein the plurality of snap-fit connectors are removably insertable into openings in the plurality of collapsible members. 
     
     
         10 . The multi-layered helmet of  claim 1 , wherein the plurality of collapsible members are removably attachable to the rigid outer shell and the flexible inner liner by a releasable ridge-and-groove connector. 
     
     
         11 . The multi-layered helmet of  claim 1 , wherein the flexible inner liner has varying thickness when measured relative to the inner surface of the rigid outer shell. 
     
     
         12 . The multi-layered helmet of  claim 1 , wherein a first portion of the plurality of collapsible members has a different rigidity than a second portion of the plurality of collapsible members. 
     
     
         13 . The multi-layered helmet of  claim 1 , wherein the plurality of collapsible members collapse to permit rotational or translational movement of the flexible inner liner relative to the rigid outer shell. 
     
     
         14 . The multi-layered helmet of  claim 1 , wherein the plurality of collapsible members collapse to permit rotational or translational movement of the outer shell relative to the flexible inner liner. 
     
     
         15 . The multi-layered helmet of  claim 1 , further comprising a chin strap configured to secure the helmet to a head of the wearer. 
     
     
         16 . A method of manufacturing a multi-layered helmet for deformably absorbing an impact to a head of a wearer, the method comprising:
 providing a rigid outer shell having an inner surface;   attaching a plurality of collapsible members to the inner surface of the rigid outer shell, the plurality of collapsible members being permanently deformable to absorb impact energy in response to a force applied to the rigid outer shell, the plurality of collapsible members having inner surfaces;   attaching a flexible inner liner to the inner surfaces of the plurality of collapsible members.   
     
     
         17 . The method of  claim 16 , wherein attaching the plurality of collapsible members and attaching the flexible inner liner comprises removably attaching the plurality of collapsible members and removably attaching the flexible inner liner, respectively. 
     
     
         18 . The method of  claim 16 , wherein removably attaching the plurality of collapsible members further comprises:
 providing a plurality of pin inserts;   forming a plurality of cavities in the plurality of collapsible members, the plurality of cavities being shaped to receive the pin inserts;   inserting the plurality of pin inserts into the plurality of cavities and into the rigid outer shell and flexible inner liner, the pin inserts removably attaching the plurality of collapsible members to the rigid outer shell and to the flexible inner liner.   
     
     
         19 . The method of  claim 16 , wherein the plurality of collapsible members are more securely removably attached to the rigid outer shell than to the flexible inner liner. 
     
     
         20 . The method of  claim 16 , further comprising:
 shaping the flexible inner liner to conform to the inner surfaces of the plurality of collapsible members and to a surface of the head of the wearer, the flexible inner liner including expansion portions to fill a plurality of voids between the plurality of collapsible members and the head of the wearer.   
     
     
         21 . The method of  claim 16 , wherein the flexible inner liner is shaped by molding the flexible inner liner to a shape of the inner surfaces of the plurality of collapsible members or rigid outer surface. 
     
     
         22 . The method of  claim 16 , wherein a first portion and a second portion of the plurality of collapsible members is attached to the inner surface of the outer shell, and the first portion has greater rigidity than the second portion of the plurality of collapsible members. 
     
     
         23 . The method of  claim 16 , wherein upon permanent deformation of at least one of the plurality of collapsible members, the method further comprises:
 detaching the flexible inner liner from the inner surfaces of the plurality of collapsible members;   detaching a consumed first collapsible member from the inner surface of the rigid outer shell, wherein the consumed first collapsible member is individually detachable relative to the plurality of collapsible members;   replacing the consumed first collapsible member with a second collapsible member, the second collapsible member having equivalent shape to the consumed first collapsible member;   reattaching the flexible inner liner to the inner surfaces of the plurality of collapsible members.   
     
     
         24 . A method of manufacturing a custom multi-layered helmet, the method comprising:
 providing a rigid outer shell having an inner surface, the inner surface of the rigid outer shell being attached to a rigid collapsible pad having an inner surface;   positioning a moldable liner blank adjacent to the inner surface of the rigid collapsible pad and adjacent to a surface of a head of a wearer, the liner blank contacting the inner surface of the rigid collapsible pad and the surface of the head simultaneously;   molding the liner blank to a shape defined by the inner surface of the rigid collapsible pad and the surface of the head;   stiffening the liner blank to retain the shape;   removably attaching the liner blank to the rigid outer shell or rigid collapsible pad.