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.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60 / 620,906 filed Oct. 21, 2004, and also is a continuation-in-part of U.S. patent application Ser. No. 10 / 933,580 filed Sep. 3, 2004, which is a continuation-in-part of U.S. patent application Ser. No. 10 / 727,725 filed Dec. 4, 2003, which claims the benefit of U.S. Provisional Patent Application Ser. No. 60 / 432,193 filed on Dec. 6, 2002, all of which are incorporated herein by reference.BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The invention relates to a method of making a custom-fitted helmet. More particularly, it relates to a method for making a custom-fitted helmet having an impact energy-absorbing liner having an inner surface that substantially conforms to the shape of the wearer's head. [0004] 2. Description of Related Art [0005] Helmets having an impact energy-absorbing liner are known for all sorts of applications, incl...

AI Technical Summary

Problems solved by technology

A problem with this method of sizing helmets is that the helmets are sized based on universal standards that are not specific to any individual who will actually wear and depend on the helmet for head protection.

While a standard sized helmet may provide adequate protection in some instances, it is not fitted to the unique shape and contour of the particular wearer's head, and therefore is prone to fit too tightly in certain aspects or along certain locations of the head while fitting too loosely in others.

A too loosely fitting helmet can be harmful because the initial impact against the outer helmet shell can be transferred to the head during a second impact between the head and the loosely fitting interior surface of the helmet.

Whereas a too tightly fitting helmet is uncomfortable to the wearer and can actually cause injury.

There are two disadvantages of these methods: 1. It is difficult when fitting a helmet to know when you have achieved the proper fit.

An improperly fitted helmet can lead to serious consequences.

As will be apparent from the above discussion, the use of any more than a minimum of fitting-foam is a waste of critical space in a helmet that could be used to absorb additional energy.

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