Adjustable helmet

Abstract

An adjustable helmet includes a main shell having a first side portion and a second side portion. The first side portion and the second side portion are laterally flexible relative to each other. The adjustable helmet includes a secondary shell coupled to the main shell at a position between the first side portion and the second side portion. At least a portion of the first side portion and at least a portion of the second side portion each extend over at least a portion of a top surface of the secondary shell. The adjustable helmet includes a tensioning device. A first end of the tensioning device is coupled to the first side portion and a second end of the tensioning device is coupled to the second side portion so as to provide tension between the first side portion and the second side portion.

Description

[0001] Related applications and priority claims

[0002] This application claims priority to the following patent applications: (1) U.S. Patent Application No. 16 / 901,363, filed on June 15, 2020, which claims priority to U.S. Provisional Application No. 62 / 911,444, filed on October 7, 2019; and (2) U.S. Provisional Application No. 62 / 911,444, filed on October 7, 2019. The disclosure of each priority patent application is fully incorporated into this document by reference. Background Art

[0003] Protective helmets are used in a variety of applications, particularly in ball games and / or contact sports such as, for example, baseball, football, hockey, lacrosse, cricket, and / or similar sports. Typically, these helmets include a single molded plastic shell layer, and an appropriate level of padding (e.g., foam padding, gel padding, etc.) depending on the application.

[0004] Typically, the size of the molded plastic shell and / or the thickness of the padding dictates the sizing parameters of the helmet. Thus, users with varying head circumferences and proportions may not be able to utilize the same helmet, and special fitting may be necessary to determine the proper helmet size for each user.

[0005] With this limitation in mind, adjustable helmets have been developed that allow a user to resize at least one portion of the helmet to fit the proportions of his or her head. However, such existing adjustable helmets typically rely on complex ratchet systems and / or locking systems to accommodate varying head circumferences. These systems can be difficult to adjust quickly and can also result in varying compression forces on different users' heads.

[0006] Thus, this document generally describes various embodiments of an adjustable helmet that allows for simplified user adjustment and substantially equal compression force regardless of the user's head size. Summary of the invention

[0007] In various embodiments, an adjustable helmet includes a main shell having a first side portion and a second side portion. The first side portion and the second side portion are laterally flexible relative to each other. The adjustable helmet includes a secondary shell coupled to the main shell at a position between the first side portion and the second side portion. At least a portion of the first side portion and at least a portion of the second side portion each extend over at least a portion of a top surface of the secondary shell. The adjustable helmet includes a tensioning device. A first end of the tensioning device is coupled to the first side portion and a second end of the tensioning device is coupled to the second side portion so as to provide tension between the first side portion and the second side portion.

[0008] The first end of the tensioner may be coupled to the first side portion at a first hardware component, and the second end of the tensioner may be coupled to the second side portion at a second hardware component. The secondary shell may include a first wing having a first elongated track formed therethrough and a second wing having a second elongated track formed therethrough. The second wing may be located on the secondary shell laterally opposite the first wing. At least a portion of the first hardware component may extend through the first elongated track, and at least a portion of the second hardware component may extend through the second elongated track. The first elongated track may be angled downward in a first direction and the second elongated track may be angled downward in a second direction such that when the first side portion and the second side portion of the primary shell flex laterally outward relative to each other, at least a portion of the secondary shell rises vertically.

[0009] The adjustable helmet may optionally include an alignment component coupled to the secondary shell. The central portion of the tensioner may be configured to couple to the alignment component. The alignment component may be vertically positioned above both the first hardware component and the second hardware component.

[0010] The first side portion of the primary shell layer may be configured to flex laterally relative to a first curved seam region formed in the primary shell layer. The second side portion of the primary shell layer may be configured to flex laterally relative to a second curved seam region formed in the primary shell layer. The secondary shell layer may be coupled to the primary shell layer at a tab formed on the primary shell layer between the first curved seam region and the second curved seam region. The secondary shell layer may be coupled to the primary shell layer by at least one fastener.

[0011] At least one of the secondary shell or the primary shell may include at least one ventilation hole formed therethrough.

[0012] The top surface of the subshell may include at least one protrusion.

[0013] The primary shell and the secondary shell may be formed from ABS injection molded plastic.

[0014] The adjustable helmet may include at least one padding stack coupled to the primary shell and at least one padding stack separately coupled to the secondary shell. The at least one padding stack coupled to the secondary shell may be configured to extend over the tensioning device but not contact the tensioning device.

[0015] In various embodiments, a method of forming an adjustable helmet includes providing a main shell. The main shell includes a first side portion and a second side portion. The first side portion and the second side portion are laterally flexible relative to each other. The method includes providing a secondary shell; coupling the secondary shell to the main shell at a position between the first side portion and the second side portion so that at least a portion of the first side portion and at least a portion of the second side portion extend over at least a portion of a top surface of the secondary shell; coupling a first hardware component to the first side portion of the main shell; coupling a second hardware component to the second side portion of the main shell; coupling a first end of a tensioning device to the first hardware component; and coupling a second end of the tensioning device to the second hardware component to provide tension between the first side portion and the second side portion.

[0016] The method may include providing a first wing on a first side of the subshell, providing a second wing on a second side of the subshell, forming a first elongated track through the first wing, and forming a second elongated track through the second wing.

[0017] The method may include extending a portion of the first hardware component through the first elongated track, and extending a portion of the second hardware component through the second elongated track.

[0018] The method may include providing a plurality of padding stacks, coupling at least one of the plurality of padding stacks to the primary shell, and coupling at least another of the plurality of padding stacks to the secondary shell. The at least another of the plurality of padding stacks coupled to the secondary shell may extend over the tensioning device but not contact the tensioning device. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 A front perspective view of an exemplary adjustable helmet is illustrated.

[0020] Figure 2 A rear perspective view of an exemplary adjustable helmet is illustrated.

[0021] Figure 3AA rear perspective view illustrating an exemplary adjustable helmet in a first configuration.

[0022] Figure 3B Example in the second configuration Figure 1 A rear perspective view of an exemplary adjustable helmet.

[0023] Figure 4 Rear plan view illustrating an adjustable helmet.

[0024] Figure 5 Illustrate an interior view of an adjustable helmet.

[0025] Figure 6 A rear perspective view illustrating an exemplary main shell of an adjustable helmet.

[0026] Figure 7 Rear perspective view illustrating an exemplary secondary shell of an adjustable helmet.

[0027] Figure 8 Rear perspective view illustrating an exemplary padding arrangement for an adjustable helmet. DETAILED DESCRIPTION

[0028] When used in this document, the singular forms "a", "an", and "the" include plural references unless the context clearly dictates otherwise. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. When used in this document, the terms "comprising" or "comprises" mean "including," but not limited to. When used in this document, the term "exemplary" is intended to mean "for example," and is not intended to indicate that a particular exemplary item is preferred or essential.

[0029] In this document, when terms such as "first" and "second" are used to modify nouns, such usage is intended only to distinguish one item from another, and is not intended to require a sequential order unless specifically stated. The terms "approximately" and "about" when used in conjunction with numerical values ​​are intended to include values ​​that are close to but not exactly the number. For example, in some embodiments, the term "approximately" may include values ​​within + / - 10% of a value.

[0030] When used in this document, terms such as "top" and "bottom," "upper" and "lower," "front" and "back," or "outer" and "inner" are not intended to have an absolute orientation, but are instead intended to describe the relative positions of various components with respect to each other. For example, when a device of which a component is a part is oriented in a first orientation, the first component may be the "upper" component and the second component may be the "lower" component. If the orientation of the structure containing the components is changed, then the relative orientation of the components may be reversed, or the components may be on the same plane. The claims are intended to include all orientations of the device containing such components.

[0031] refer to Figure 1 to Figure 2 , illustrating an adjustable helmet 10 according to one aspect of the present disclosure. In the embodiments shown throughout, the adjustable helmet 10 is configured as a batting helmet for use as part of a sporting activity such as, for example, baseball and / or softball. However, it will be understood that the various systems and configurations described in this document are not limited to use in batting helmets, and may be applied to helmets used for other sports (e.g., hockey, football, lacrosse, cricket, cycling, racing, etc.) and / or for use in other non-sporting applications (e.g., protective helmets for construction, emergency responders, etc.).

[0032] The adjustable helmet 10 includes a main shell 12 and a secondary shell 29. As will be described in further detail below, the secondary shell 29 can be formed separately from the main shell 12 and can be coupled to the main shell so as to allow movement of the shells relative to each other. Both the main shell 12 and the secondary shell 29 can be formed of any suitable material such as, for example, ABS injection molded plastic, polypropylene, etc., and can have any suitable thickness (e.g., 2 mm to 5 mm). However, it will be understood that the main shell 12 and the secondary shell 29 can be formed of different materials and / or have different thicknesses. In addition, each of the main shell 12 and / or the secondary shell 29 can vary in overall thickness to account for areas of greater impact strength, greater flexibility, etc.

[0033] The main shell 12 may include a brim portion 14 and a pair of ear flaps 16 having ear holes 18. Although a pair of ear flaps 16 are shown, it will be understood that the main shell 12 may be configured to have less than two ear flaps 16 (e.g., one ear flap or no ear flaps). In addition, each ear flap 16 may include a plurality of mounting holes 17 for selective attachment of, for example, cheek guards (multiple), belts (multiple), masks, etc. In addition, it should be understood that the main shell 12 may not have a brim or may have a brim that is smaller than the brim. Figure 1 An alternative style of hat brim to the one illustrated in .

[0034] Still reference Figure 1 to Figure 2, the main shell 12 may include two respective side portions: a first side portion 20A and a second side portion 20B. Proximate to the front region of the main shell 12, respective seam sections 21A, 21B are formed. Each seam section 21A, 21B may be configured as a cutout in the main shell 12 that allows the respective first side portion 20A and second side portion 20B to flex laterally relative to other portions of the main shell 12 and relative to the secondary shell 29. As will be described in further detail below, such lateral flexibility enables the helmet 10 to be size-adjustable. In various embodiments, one or more of the seam sections 21A, 21B may have a curved configuration. In other embodiments, one or more of the seam sections 21A, 21B may have different shapes or configurations.

[0035] Because each seam region 21A, 21B can be curved, lateral deflection of the respective side portions 20A, 20B to a certain maximum point is achievable without splitting or otherwise damaging the main shell layer 12. For example, referring to Figure 3A and Figure 3B , the helmet 10 is in its minimum expanded configuration ( Figure 3A ) and its maximum expansion configuration ( Figure 3B ) where the respective side portions 20A, 20B flex laterally inwardly or outwardly depending on the proportions of the user's head. As the user slides the helmet 10 over his or her head, the side portions 20A, 20B flex accordingly, thereby providing the user with an infinitely adjustable fit between a minimum configuration and a maximum configuration. In some embodiments, the determination of the minimum and maximum expanded configurations may be based on commonly utilized hat sizes. For example, the minimum expanded configuration ( Figure 3A ) can be based on a 6 3 / 8 hat size, while the maximum expansion configuration ( Figure 3B ) may be based on a 7 5 / 8 hat size, with the helmet 10 infinitely adjustable to any head size within that range. However, it will be understood that the determination of the minimum and maximum configurations is not limited to these described ranges.

[0036] Reference Figure 1 to Figure 2, the secondary shell 29 may include a peak portion 22. The peak portion 22 may be raised relative to the remainder of the secondary shell 29 by a pair of side surfaces 28A, 28B so that the peak portion is substantially flush with the outer surfaces of the side portions 20A, 20B of the main shell 12. The main shell 12 itself may be raised relative to the secondary shell 29 by side portions 32A, 32B. The peak portion 22 may include an opening 24 for insertion of a fastener (not shown) to couple the secondary shell 29 to the main shell 12. Any suitable fastener may be utilized, such as, for example, screws, rivets, etc. The secondary shell 29 may further include one or more ventilation openings 30 substantially adjacent to the peak portion 22 to allow air to enter the helmet 10 through the secondary shell 29. The secondary shell 29 may extend from the peak portion 22 to a bottom portion 31, and the bottom portion 31 extends as low (or substantially as low) as the side portions 20A, 20B to provide adequate protection to the back of the user's head.

[0037] refer to Figure 1 to Figure 2 and Figure 4 , the primary shell 12 may include a pair of inlay portions 26. Each inlay portion 26 may include one or more ventilation openings 27. The inner surface of the inlay portion 26 may be substantially flush with the inner surface of the secondary shell 29, thereby allowing any padding attached within the top interior portion of the helmet 10 to have a consistent thickness and depth for improved fit and user comfort.

[0038] like Figure 2 and Figure 4 As shown in FIG. 1 , a pair of fasteners 33A, 33B may be coupled to (and extend through) respective side portions 20A, 20B of the main shell 12. More specifically, the fasteners 33A, 33B may extend through respective openings 45A, 45B formed in the main shell 12, such as Figure 6 . The fasteners 33A, 33B may be any suitable fasteners, such as, for example, screws. As will be further described below, the fasteners 33A, 33B may form part of a tensioning device used to enable lateral flexure of the side portions 20A, 20B, but still provide a secure and comfortable fit of the helmet 10 on the user's head. Although a pair of fasteners 33A, 33B are illustrated, it should be understood that an alternative number of fasteners may be used within the scope of the present disclosure.

[0039] refer to Figure 5, showing an interior view of the helmet 10. As described above, the helmet 10 includes a tensioning device 40 that enables expansion and contraction of the side portions 20A, 20B while providing substantially equal compressive force regardless of the size of the user's head. In some embodiments, the tensioning device 40 may include an elastic tension cord 36 that extends between and is coupled to respective internal components 44A, 44B that are coupled to the fasteners 33A, 33B. According to various embodiments, one or more of the internal components 44A, 44B may be a nut. A pair of connectors 39A, 39B (e.g., shoulder screws) may be utilized to retain the looped ends 38A, 38B of the tension cord 36 so that the tension cord 36 moves in unison with any flexing of the side portions 20A, 20B. The tension cord 36 may be any suitable size and material (e.g., a 3 / 32 inch diameter abrasion resistant elastic cord), and the looped ends 38A, 38B may be formed by any suitable method (e.g., deburred crimped wire). In some embodiments, the tension cord 36 may have a length of, for example, between 3 inches and 4 inches. Additionally, while a tension cord 36 is shown and described, it will be appreciated that any other suitable tensioning device may be utilized, such as, for example, one or more rubber bands, one or more springs, etc. As another example, the tensioning device may include a molded rubber or thermoplastic polyurethane component.

[0040] The central portion of the tensioner 40 is configured to contact an alignment member 42 that is attached to the inner surface of the secondary shell 29 at a mounting point 43. According to one embodiment, the alignment member 42 may be a nut. For example, the central portion of the tensioner 40 may pass over or be supported by the alignment member 42. The alignment member 42 may not physically hold or hinder the movement of the tensioner 40. Instead, the alignment member 42 may act as a centering point so that the tension imposed on the respective side portions 20A, 20B by the tensioner 40 is substantially equal. In addition, as shown in FIG. Figure 5 As shown in FIG. 1 , the alignment member 42 can be located vertically above the inner members 44A, 44B, which allows the length of the tensioner 40 to be greater than if the tensioner passed directly between the inner members 44A, 44B. In the case of a longer tensioner 40, the tensioner 40 is at its largest point (i.e., Figure 3B ) and its minimum point (i.e., Figure 3A) is minimal. For example, in the smallest size configuration, the tensioning device 40 may have a force preload of, for example, about 1 pound, while in the largest size configuration, the tensioning device may have a force of, for example, 3 pounds or less. Thus, regardless of head size, all users will experience similar compressive forces, and thus similar levels of fit and comfort, because the variance in compressive forces described above has been found to be barely perceptible to the user.

[0041] Still reference Figure 5 , proximate to the bottom portion 31, the secondary shell 29 may include a pair of opposing wings 34A, 34B. Each wing 34A, 34B may have a corresponding elongated track 35A, 35B formed therethrough. A portion of a corresponding track hardware assembly 52A, 52B (the corresponding track hardware assembly is composed of fasteners 33A, 33B, internal components 44A, 44B, and connectors 39A, 39B) extends through the corresponding track 35A, 35B. In this way, the tracks 35A, 35B can define the minimum and maximum adjustment limits for the helmet 10. In some embodiments, at least a portion of each track hardware assembly 52A, 52B can be configured to be cylindrical (or substantially cylindrical), which can enable that portion of the track hardware assembly to freely and smoothly traverse the tracks 35A, 35B during a user's trial fit of the helmet 10.

[0042] In some embodiments, one or more tracks 35A, 35B may be angled in a downward direction from the proximal end of the wing 34A, 34B (i.e., the end closest to the center of the secondary shell 29) to the proximal end of the wing 34A, 34B (i.e., the end farthest from the center of the secondary shell 29). This angling of the tracks 35A, 35B may act to lift the bottom portion 31 of the secondary shell 29 in an upward direction as the corresponding side portion 20A, 20B flexes to accommodate the user's head. In this way, any vertical gap formed between the outer surface of the secondary shell 29 and the inner surface of the main shell 12 due to the flexure / separation of the side portions 20A, 20B can be accounted for (and closed) by the corresponding upward movement of the secondary shell 29 by the contact of the track hardware with the angled tracks 35A, 35B. Such movement may be possible because the secondary shell 29 may be attached to the main shell 12 at only one point. For example, as Figure 6 As shown in FIG. 4 , the main shell 12 may include a tab 48 having an opening 49. The peak portion 22 may be provided by, for example, extending through the opening 24 ( Figure 1 ) and openings 49 are coupled to tabs 48 by fasteners. Alternatively, secondary shell 29 may be coupled to primary shell 12 by non-fastener means (e.g., adhesive), or the secondary shell may be integrally formed (or molded together) with the primary shell at or near the location of tabs 48.

[0043] When the user initially places the helmet 10 on his or her head, the side portions 20A, 20B may flex laterally, thereby causing the fasteners 33A, 33B (and coupled inner components 44A, 44B) to move relative to the tracks 35A, 35B accordingly. Such movement of components 44A, 44B may cause the coupled tensioning device 40 to extend, thereby slightly increasing the tension on the tensioning device. Once the user completes placement of the helmet 10 on his or her head, the tension from the tensioning device 40 may act on the inner components 44A, 44B (and coupled fasteners 33A, 33B) to pull the side portions 20A, 20B inwardly to create a secure and comfortable fit on the user's head without the need for a ratchet mechanism, locking mechanism, etc.

[0044] Although the use of only one tensioner is shown and described in the present disclosure, it will be understood that more than one tensioner (and thus, additional track hardware assemblies, additional wings, additional elongated tracks, and / or other components) may be utilized in accordance with one or more other embodiments of the present disclosure.

[0045] refer to Figure 7 , showing a detailed view of the outer surface of an exemplary secondary shell 29. As described above, the secondary shell 29 can be embedded relative to the main shell 12, and the side portions 20A, 20B of the main shell 12 can be laterally flexed relative to the secondary shell 29. Specifically, the side portions 20A, 20B can move laterally relative to the corresponding top surfaces 50A, 50B of the secondary shell 29. In order to minimize the friction between the side portions 20A, 20B of the main shell 12 and the top surfaces 50A, 50B of the secondary shell 29, the secondary shell 29 may include one or more protrusions 46A, 46B. The purpose of the protrusions 46A, 46B is to provide a purposeful friction surface between the main shell 12 and the secondary shell 29. This friction surface can limit the friction area between the two shells and allow smoother movement of the side portions 20A, 20B on the top surfaces 50A, 50B of the secondary shell 29. While two protrusions 46A, 46B are shown, it will be appreciated that additional or fewer protrusions 46A, 46B may be utilized.

[0046] Reference now Figure 8, showing an exemplary padding arrangement 60 according to one aspect of the present disclosure. One or more pads in the padding arrangement 60 may be formed of any suitable material such as, for example, ethylene vinyl acetate (EVA) foam, polyurethane (PU) die-cut comfort foam, and / or a combination thereof. In addition, the pads in the padding arrangement may have the same or different thicknesses. The padding arrangement 60 may include a front padding stack 62, a top padding stack 64, and / or one or more ear pads 65. In use with the helmet 10 described above, the front padding stack 62 and / or the ear pad (s) 65 may be configured to be bonded to at least a portion of the main shell 12. Such bonding may be by any suitable method such as, for example, gluing, tying with a strap, etc. Therefore, the front padding stack 62 and / or the ear pad (s) 65 may be able to move in unison with the movement of the side portions 20A, 20B of the main shell 12, thereby ensuring a safe and proper fit for the user. The top gasket stack 64 may be configured to be bonded to at least a portion of the primary shell 12, at least a portion of the secondary shell 29, and / or at least a portion of both the primary shell and the secondary shell.

[0047] Additionally, the padding arrangement 60 may include a rear padding stack 66. The rear padding stack 66 may be configured to be bonded to the secondary shell 29. Thus, the rear padding stack 66 may be able to move in unison with the secondary shell 29. The geometry of the secondary shell 29 may allow the rear padding stack 66 to be positioned within the primary shell 12.

[0048] like Figure 8 As further shown in , the rear padding stack 66 can be configured to cover at least a portion of the tensioning device 40 described above without interfering with the operation of the tensioning device. The rear padding stack 66 can include a lower adhesive surface 68 that can be configured to be bonded to, for example, the lower portion 31 of the secondary shell 29, while an upper adhesive surface 67 can be provided for bonding the rear padding stack 66 to the secondary shell 29 at a location above the tensioning device 40. In this manner, the tensioning device 40 can be able to operate without interference, and the user may not feel or otherwise be aware of the presence of the various components of the tensioning device 40 due to the overlying padding. The rear padding stack 66 can cover substantially the entire rear of the helmet 10, the primary shell 12, and the secondary shell 29 in all adjustment configurations.

[0049] In various embodiments, the bond points of the rear padding stack 66 can be positioned so that when the helmet 10 is adjusted, the wings 34A, 34B of the secondary shell 29 can flex and not collide with the track hardware assemblies 52A, 52B.

[0050] Although the rear padding stack 66 is illustrated as a single padding stack having two adhesive surfaces, it will be understood that the rear padding stack 66 can be formed as two (or more) separate padding stacks. It should also be understood that in various embodiments, alternative padding arrangements and / or configurations can be used with the adjustable helmet 10 described in the present disclosure.

[0051] As described above, the adjustable helmet 10 described in this document is configured as a batting helmet for use in, for example, baseball and / or softball. However, it will be understood that the various systems and configurations described in this document (including the tensioning device 40) are not limited to use in batting helmets and may be applied to helmets used for other sports (e.g., hockey, football, lacrosse, cricket, cycling, racing, etc.) and / or for use in other non-sporting applications (e.g., protective helmets for construction, emergency responders, etc.).

[0052] The features and functions described above, as well as alternatives, may be combined into many other different systems or applications. Various alternatives, modifications, changes or improvements may be made by those skilled in the art, each of which is also intended to be covered by the disclosed embodiments.

Claims

1. An adjustable helmet comprising: A main shell layer, the main shell layer comprising: a first side portion, and The second side portion, wherein the first side portion and the second side portion are laterally flexible relative to each other between a first position and a second position; a secondary shell layer coupled to the primary shell layer at a location between the first side portion and the second side portion, wherein at least a portion of the first side portion and at least a portion of the second side portion each extend over at least a portion of a top surface of the secondary shell layer; a tensioning device comprising an elastic member, wherein a first end of the elastic member is connected to the first side portion and a second end of the elastic member is connected to the second side portion to provide tension between the first side portion and the second side portion, the tension biasing the first side portion and the second side portion toward the first position; and An alignment member is coupled to the resilient member, wherein the alignment member provides a centering point that distributes the tension equally between the first side portion and the second side portion when the first side portion and the second side portion flex relative to each other.

2. The adjustable helmet of claim 1, wherein the first end of the tensioner is coupled to the first side portion at a first hardware component, and the second end of the tensioner is coupled to the second side portion at a second hardware component.

3. The adjustable helmet of claim 2, wherein the secondary shell comprises: a first wing having a first elongated track formed therethrough; and A second wing having a second elongated track formed therethrough, wherein the second wing is located on the secondary shell laterally opposite the first wing.

4. The adjustable helmet of claim 3, wherein: At least a portion of the first hardware component extends through the first elongated track, At least a portion of the second hardware component extends through the second elongated track.

5. The adjustable helmet of claim 4, wherein the first elongated track is angled downward in a first direction and the second elongated track is angled downward in a second direction such that when the first side portion and the second side portion of the primary shell are flexed laterally outward relative to each other, at least a portion of the secondary shell is vertically raised.

6. The adjustable helmet of claim 2, wherein the alignment feature is coupled to the secondary shell, wherein a central portion of the elastic member is coupled to the alignment feature.

7. The adjustable helmet of claim 6, wherein the alignment feature is positioned vertically above both the first hardware component and the second hardware component.

8. The adjustable helmet of claim 1 , wherein the first side portion of the main shell layer is configured to flex laterally relative to a first curved seam area formed in the main shell layer, and the second side portion of the main shell layer is configured to flex laterally relative to a second curved seam area formed in the main shell layer.

9. The adjustable helmet of claim 8, wherein the secondary shell layer is coupled to the primary shell layer at a tab formed on the primary shell layer between the first curved seam area and the second curved seam area.

10. The adjustable helmet of claim 9, wherein the secondary shell is coupled to the primary shell by at least one fastener.

11. The adjustable helmet of claim 1 , wherein at least one of the secondary shell or the primary shell includes at least one ventilation hole formed therethrough.

12. The adjustable helmet of claim 1, wherein the primary shell and the secondary shell are formed of acrylonitrile butadiene styrene (ABS) injection molded plastic.

13. The adjustable helmet of claim 1, further comprising at least one padding stack coupled to the primary shell layer and at least one padding stack separately coupled to the secondary shell layer.

14. The adjustable helmet of claim 13, wherein the at least one padding stack coupled to the secondary shell is configured to extend over the tensioning device but not contact the tensioning device.

15. The adjustable helmet of claim 1, wherein the first position is smaller than the second position.

16. A method of forming an adjustable helmet, the method comprising: A main shell is provided, the main shell comprising: a first side portion, and The second side portion, wherein the first side portion and the second side portion are laterally flexible relative to each other between a first position and a second position; Provide a subshell; coupling the secondary shell to the primary shell at a location between the first side portion and the second side portion such that at least a portion of the first side portion and at least a portion of the second side portion extend over at least a portion of a top surface of the secondary shell; coupling a first hardware component to the first side portion of the main housing; coupling a second hardware component to the second side portion of the main housing; connecting a first end of the elastic member to the first hardware component; connecting a second end of the resilient member to the second hardware component to provide tension between the first side portion and the second side portion, the tension biasing the first side portion and the second side portion toward the first position; and An alignment feature is coupled to the resilient feature, wherein the alignment feature provides a centering point that distributes the tension equally between the first side portion and the second side portion when the first side portion and the second side portion flex relative to each other.

17. The method of claim 16, further comprising: providing a first wing on a first side of the subshell; providing a second wing on a second side of the secondary shell; forming a first narrow and long track through the first wing; and A second elongated track is formed through the second wing.

18. The method of claim 17, further comprising: extending a portion of the first hardware component through the first elongated track; and A portion of the second hardware component is extended through the second elongated track.

19. The method of claim 16, further comprising: Providing multiple litter stacks; coupling at least one of the plurality of padding stacks to the main shell; and At least one other of the plurality of dunnage stacks is coupled to the subshell, wherein the at least one other of the plurality of dunnage stacks coupled to the subshell extends over a tensioning device but does not contact the tensioning device.

20. The method of claim 16, wherein the first position is smaller than the second position.

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