Energy Absorbing Chin Protector

Abstract

A device is intended to be worn over the chin of a wearer. The device comprises a compliant first layer, a rigid second layer coupled to the first layer and displaced farther from the wearer than the first layer, and an energy absorbing layer positioned between the first layer and the second layer. The first layer and the second layer are moveable toward one another. The energy absorbing layer is operable to dissipate a transfer of energy between the first layer and the second layer.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 780,078, filed on Mar. 28, 2025, U.S. Provisional Application No. 63 / 763,868, filed on Feb. 26, 2025 and U.S. Provisional Application No. 63 / 663,908, filed on Jun. 25, 2024. The entire disclosure of each application is incorporated herein by reference.GOVERNMENT LICENSE RIGHTS

[0002] This invention was made with government support under 2R44NS119134-03A1 awarded by the National Institutes of Health. The government has certain rights in the invention.FIELD

[0003] The present disclosure relates to an energy absorbing device that attaches to the chin of a wearer, intended to attenuate the severity of impacts to the chin or to a helmet to which the energy absorbing device is affixed.BACKGROUND

[0004] This section provides background information related to the present disclosure which is not necessarily prior art.

[0005] Energy absorbing materials and structures are frequently used in a variety of applications, including helmets and other personal protective equipment. Chinstraps and other chin protector devices are commonly included in helmet products and often serve to ensure that a helmet remains coupled to a wearer's head during typical use of the helmet or during an impact to the head. Chin protectors are small, lightweight devices that must also meet comfort requirements of helmet wearers. During certain impacts to a helmet, a chinstrap or other chin protector device may undergo significant loading. Inclusion of energy absorbing technology in a chin protector could serve to better protect a helmet wearer from injury to the chin, teeth, head, or brain.SUMMARY

[0006] This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features.

[0007] In one embodiment of the present disclosure, a chin protector contains an energy absorbing layer comprised of one or more energy absorbing structures that is displaced between a first layer that is nearer to a wearer's chin and a second layer that is farther from a wearer's chin, wherein the energy absorbing layer attenuates the severity of an impact as it is compressed between the two layers when the chin applies a force to the first layer.

[0008] In another embodiment of the present disclosure, a chin protector contains an energy absorbing layer comprised of one or more energy absorbing structures that is displaced between a first layer that is nearer to a wearer's chin and a second layer that is farther from a wearer's chin, wherein the second layer has holes or gaps in its design that allow for a portion of the energy absorbing layer to pass through temporarily as the energy absorbing layer is compressed.

[0009] In another embodiment of the present disclosure, a chin protector contains at least one fluid-filled bladder displaced between a first layer and a second layer, wherein the fluid travels from the bladder to a reservoir in a section of the chin protector that is not subjected to compressive loading when the first layer and second layer move nearer to each other.

[0010] In another embodiment of the present disclosure, a chin protector contains an energy absorbing layer comprised of one or more energy absorbing structures that is displaced between a first layer that is nearer to a wearer's chin and a second layer that is farther from a wearer's chin, wherein the second layer is connected to a helmet shell or protective mask.

[0011] In at least one embodiment a device is intended to be worn over the chin of a wearer. The device comprises a compliant first layer, a rigid second layer coupled to the first layer and displaced farther from the wearer than the first layer, and an energy absorbing layer positioned between the first layer and the second layer. The first layer and the second layer are moveable toward one another. The energy absorbing layer is operable to dissipate a transfer of energy between the first layer and the second layer.

[0012] In another arrangement, a device is intended to be worn over the chin of the wearer. The device includes a compliant first layer, a rigid second layer coupled to the first layer and displaced farther from the wearer than the first layer, and an energy absorbing layer positioned between the first layer and the second layer. The second layer includes a translucent portion providing a line of sight to the energy absorbing layer.

[0013] Another embodiment of the present disclosure includes a device intended to be worn over the chin of the wearer. The device includes a first layer, a rigid second layer displaced farther from the wearer than the first layer, and an energy absorbing layer positioned between the first layer and second layer. The energy absorbing layer includes a fluid filled bladder in communication with a reservoir.

[0014] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations and are not intended to limit the scope of the present disclosure.

[0016] FIG. 1A is a view of a helmet incorporating an energy absorbing chin protector.

[0017] FIG. 1B is a cross-sectional view of an energy absorbing chin protector with an energy absorbing layer and straps for connecting to a helmet.

[0018] FIG. 2A is a cross-sectional view of an energy absorbing chin protector with a single energy absorbing structure in its energy absorbing layer.

[0019] FIG. 2B is a cross-sectional view of an energy absorbing chin protector with multiple energy absorbing structures in its energy absorbing layer.

[0020] FIG. 20 is a cross-sectional view of an energy absorbing chin protector with a continuous energy absorbing material in its energy absorbing layer.

[0021] FIG. 3A is a cross-sectional view of an energy absorbing chin protector with a second layer with holes or gaps in it through which an energy absorbing material or structure may extend.

[0022] FIG. 3B is a cross-sectional view of an energy absorbing chin protector with a second layer with holes or gaps in it through which one or more reservoirs may expand through when one or more connected fluid-filled bladders are compressed.

[0023] FIG. 4A is a cross-sectional view of an energy absorbing chin protector with support materials surrounding an energy absorbing layer.

[0024] FIG. 4B is a cross-sectional view of an energy absorbing chin protector with support materials surrounding an energy absorbing layer that is undergoing compression.

[0025] FIG. 5 is a cross-sectional view of an energy absorbing chin protector containing fluid-filled bladders, with reservoirs in its helmet straps.

[0026] FIG. 6A is a front view of a protective mask containing an energy absorbing chin protector.

[0027] FIG. 6B is a cross-sectional view of the chin area of a protective mask containing an energy absorbing chin protector.

[0028] FIG. 7A is an isometric view of a helmet containing an energy absorbing chin protector.

[0029] FIG. 7B is a cross-sectional view of the chin area of a helmet containing an energy absorbing chin protector.

[0030] FIG. 8A is a cross-sectional view of an energy absorbing chin protector comprised of a comfort layer, first layer, and an energy absorbing layer.

[0031] FIG. 8B is a cross-sectional view of an energy absorbing chin protector comprised of a comfort layer and an energy absorbing layer.

[0032] FIG. 8C is a cross-sectional view of an energy absorbing chin protector comprised of a comfort layer, a first layer, and an energy absorbing layer, with a helmet strap passing through the energy absorbing layer.

[0033] FIG. 9A is a cross-sectional view of an energy absorbing chin protector comprised of an inner layer, an outer layer, and a shock absorbing structure disposed between the inner layer and outer layer.

[0034] FIG. 9B is a cross-sectional view of an energy absorbing chin protector comprised of an inner layer, an outer layer, and a shock absorbing structure disposed between the inner layer and outer layer, wherein the shock absorbing structure is compressed.

[0035] FIG. 10A is an exterior view of an energy absorbing chin protector.

[0036] FIG. 10B is an interior view of an energy absorbing chin protector showing a shock absorbing structure inside.

[0037] FIG. 11 is a graph showing results of impact testing to the facemask of a helmet while different chinstraps are equipped to the helmet.

[0038] FIG. 12 is a perspective view of an interior of an energy absorbing chin protector.

[0039] FIG. 13A is a perspective view of an interior of an energy absorbing chin protector including an outer layer with a translucent portion.

[0040] FIG. 13B is another perspective view of the chin protector shown in FIG. 13A.

[0041] FIG. 14 is an exploded perspective view of another alternate embodiment chin protector.

[0042] FIG. 15 is another exploded perspective view of the chin protector depicted in FIG. 14.

[0043] FIG. 16 is a cross-sectional view taken through the chin protector depicted in FIGS. 14 and 15.

[0044] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.DETAILED DESCRIPTION

[0045] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0046] The present disclosure relates to chin protectors or chinstraps for use with helmets or other head protective devices. The present disclosure includes embodiments of such devices that provide protection, comfort, and other benefits to wearers.

[0047] Impacts to the head are common in many settings, such as in sports, military activities, cycling, horseback riding, motorcycle riding, automotive crashes, and workplace incidents. In these settings, helmets are often worn to protect the head of a wearer from such impacts. Helmets often comprise various components, such as: an exterior shell, an energy absorbing liner, comfort padding that interfaces directly with the wearer's head, a visor, a facemask or face cage, and a chinstrap or chin protector. Depending on the design and intended use of the helmet, some, or all of these components may be present. In several helmet designs for various purposes, the chinstrap or chin protector serves multiple functions. First, the chinstrap or chin protector may serve to retain the helmet on the head and secure its positioning while the wearer is at rest, in motion, or sustaining an impact to the helmet. The chinstrap or chin protector provides another point of contact on the head that enables the helmet to remain in a desired orientation while the helmet is in use. Second, the chinstrap or chin protector may protect the chin and lower jaw region from direct impacts. The chinstrap or chin protector may protect a wearer from skin abrasion, jaw fracture, dental injury, bruising, or other injuries when the chin or jaw area are struck by a projectile, surface (e.g., ground, wall, etc.), or another person. Third, the chinstrap or chin protector may protect the wearer's brain from traumatic brain injury or concussion. In some helmets, the chinstrap or chin protector plays a role in absorbing impact energy when an impact occurs to the helmet shell or facemask or face cage. The chinstrap or chin protector can attenuate some of this energy and reduce the acceleration of the head resulting from these impacts, thus lowering the risk of resulting injury. The facemask of the helmet may be a region of the helmet particularly susceptible to receiving repeated impacts; for example, in American football, recent peer-reviewed studies have reported that approximately half of the impacts an athlete sustains are to the facemask. Lacrosse and ice hockey also feature helmets with facemasks or face cages, which may also pose risk for impact. Other sports may feature similar helmet designs.

[0048] In one embodiment of the present disclosure, a chin protector may cover a wearer's chin and be connected to a helmet through use of straps and / or buckles. FIG. 1A displays a helmet comprising an energy absorbing chin protector and other helmet components. FIG. 1A shows the full helmet system as worn by a wearer. The helmet 100 consists of a helmet shell 101, a facemask 104, and an energy absorbing chin protector 102. The helmet 100 is worn on the head 106 of a wearer. The energy absorbing chin protector 102 is affixed to the helmet shell 101 by helmet straps 103 and buckles 105 on the straps that connect to the shell. In some embodiments, the energy absorbing chin protector 102 may not make use of buckles, but instead use helmet straps 103 that tie or wrap around a facemask 104 or face cage to secure to the helmet. In other embodiments, the energy absorbing chin protector may connect to a helmet 100 by sliding into clips on the outside of the helmet shell 101.

[0049] FIG. 1B shows an expanded, cross-sectional view of energy absorbing chin protector 102. An energy absorbing layer 109 is displaced between a first layer 107 and a second layer 108. When the chin protector is worn, the first layer 107 is nearer to the wearer than the second layer 108. The energy absorbing layer 109 occupies the space between the first layer 107 and second layer 108 only partially in some embodiments, while in other embodiments, the space is occupied completely. The chin protector may be connected to a helmet or head-covering device by helmet straps 103. The helmet straps 103 may connect to the chin protector through holes, slots, rivets, buckles, or stitching on the second layer 108. In some embodiments, the helmet straps 103 may connect to other sections of the chin protector, such as the first layer 107, the energy absorbing layer 109, or a combination of the first layer 107, second layer 108, and energy absorbing layer 109. When worn on a chin 111, the helmet straps 103 may pull the chin protector towards the chin 111 during an impact to the helmet shell 101 or the facemask 104. This will cause the chin 111 to exert a force on the first layer 107, which will then cause the first layer and second layer to move nearer to one another, compressing the energy absorbing layer 109 in the process. In some embodiments, the first layer 107 may make direct contact with the wearer's chin 111. In other embodiments, there may be a comfort layer 110 between the first layer 107 and wearer's chin 111, intended to make the wearer's contact with and use of the energy absorbing chin protector more comfortable.

[0050] In some embodiments, the first layer 107 may be substantially rigid. The first layer 107 may be created from a plastic, a metal, a composite material, a rigid foam, or another substantially stiff material that would allow a wearer's chin to apply a force to the first layer 107 without noticeably deforming or bending it. In such embodiments, it may be desirable to attach a comfort layer 110 of soft material to the first layer that could provide a comfortable interface between the chin protector and the wearer. This comfort layer 110 may be a foam, a fabric, an elastomer, a rubber, a 3D printed material, silicone, or another material that is softer and / or less abrasive than the first layer 107. The comfort layer 110 may also possess moisture-wicking or antimicrobial properties. Additionally, comfort layer 110 may be an optional component of the energy absorbing chin protector that a user can choose to apply only if desired. Furthermore, the comfort layer 110 could be replaced by a user if it does not fit properly or begins to develop an unpleasant odor or appearance after extended use. In other embodiments, the first layer 107 itself may be created from a substantially soft material, such that the first layer 107 provides a comfortable interface between the chin protector and the wearer. In such embodiments, the first layer 107 may be created from a foam, a fabric, an elastomer, a rubber, a 3D printed material, silicone, or another reasonably soft material.

[0051] The material used to create the energy absorbing layer and the overall shape, size, and structure of the energy absorbing layer may vary across different embodiments of the present disclosure. FIGS. 2A-2C shows cross-sectional views of example embodiments of the energy absorbing chin protector 200A, 200B, 200C with different energy absorbing layers.

[0052] In FIG. 2A, the energy absorbing layer exists between a first layer 201 and second layer 202. In this embodiment, the energy absorbing layer consists of a single energy absorbing structure 204. The energy absorbing structure 204 may not fill the entirety of the space between the first layer 201 and the second layer 202, and gaps 205 may exist around the energy absorbing structure 204. The energy absorbing chin protector 200A may have helmet straps 203 for connecting to a helmet or head protective device. The first layer 201 may be comprised of a material that is substantially comfortable for contacting a wearer's chin. Examples of such a material include ethylene-vinyl acetate (EVA) foam, viscoelastic foams such as Poron XRD or D3O, 3D printed lattice materials, polyurethane foam, vinyl nitrile foam, memory foam, nylon fabric, cotton fabric, polyester fabric, an air-filled bladder, or a liquid-filled bladder. Meanwhile, the second layer 202 may serve as an exterior shell and be formed from a substantially rigid material. Examples of a substantially rigid material for the second layer 202 include acrylonitrile butadiene styrene, polycarbonate, polyactic acid plastic, high-density polyethylene, recycled plastics, metals such as titanium or aluminum, or rigid foams such as expanded polystyrene (EPS) or expanded polypropylene (EPP).

[0053] FIG. 2B displays another embodiment of the energy absorbing chin protector 200B in which a plurality of energy absorbing structures 204 exists between the first layer and second layer. In this embodiment, multiple energy absorbing structures 204 are distributed throughout the energy absorbing layer that exists between the first layer and second layer. As such, multiple gaps 205 are present in the design that exist between the multiple energy absorbing structures 204. Gaps 205 are functional elements in that they reduce the weight of the chin protector, reduce the cost by reducing the quantity of material, and also improve ventilation. The number of discrete energy absorbing structures present may range from 1 to 100, depending on their size and weight. Additionally, it should be appreciated that the mechanical properties of portions of energy absorbing structure 204 may vary. For example, the structures 204 that are centralized and labeled 204a may exhibit a greater stiffness than the other structures 204.

[0054] FIG. 2C displays another embodiment of the energy absorbing chin protector 200C in which a single, continuous layer of material is used to create the energy absorbing structure 204 in the energy absorbing layer that exists between the first layer 201 and the second layer 202. In this embodiment, the energy absorbing structure may fill the entirety of the space between the first layer and the second layer or a majority of the space. Upon compression of the chin protector resulting from an impact (i.e., the first layer moves nearer to the second layer), the energy absorbing structure(s) will compress and attenuate the force that is transferred to the chin and / or head of the wearer. In most embodiments, the total thickness of the energy absorbing chin protector will range from 5 mm to 60 mm. The thickness of energy absorbing layer will range from 3 mm to 50 mm in most embodiments.

[0055] A variety of materials can be used to create the energy absorbing structures 204 in the energy absorbing layer. These materials may include various foams, including expanded polystyrene, expanded polypropylene, or viscoelastic foams such as Poron XRD or D3O. These materials may also include 3D printed lattice structures. Silicone could also be used as a material to create the energy absorbing structures. Furthermore, buckling beams or buckling cones may be used as the energy absorbing structures in the energy absorbing layer. Fluid-filled bladders, such as those filled with air or a liquid, may also be used to create the energy absorbing structures 204 of the energy absorbing layer. The materials and structures used in the energy absorbing layer may be capable of withstanding up to thousands of cycles of compressive loading.

[0056] FIG. 3A displays a cross-sectional view of an embodiment of an energy absorbing chin protector 300A with an expanding energy absorbing layer. Energy absorbing chin protector 300A may consist of a first layer 301 and a second layer 302. The energy absorbing chin protector may have helmet straps 305 for connecting to a helmet or head protective device. The energy absorbing chin protector is designed to be worn on the chin 306 of a wearer and, in some embodiments, may have a comfort layer 304 affixed to the first layer 301 for making contact with the chin 306. FIG. 3A shows an embodiment in which an energy absorbing layer consists of an energy absorbing structure 303 and exists between the first layer 301 and the second layer 302. The second layer may serve as a rigid shell for the energy absorbing chin protector. The second layer 302 may have gaps or holes in its design which allow for the energy absorbing structure 303 to protrude beyond it in a direction distal to the first layer 301. Upon compression of the energy absorbing chin protector (i.e., the first layer 301 moves nearer to the second layer 302), the energy absorbing structure 303 may expand or press through gaps or holes 310 in the second layer 302. In an example embodiment, the energy absorbing structure 303 may be a foam that is pushed out through the holes in the second layer 302 when compressed by the first layer 301.

[0057] FIG. 3B displays an embodiment in which a similar energy absorbing chin protector 300B has a second layer 302 with gaps or holes 310 in its design. In this embodiment, fluid-filled bladders 307 serve as the energy absorbing structures in between the first layer 301 and second layer 302. The fluid-filled bladders 307 are connected to reservoirs 308 that are oriented near to or within the holes or gaps 310 in the second layer 302 such that when the fluid-filled bladders 307 are compressed, the reservoirs will fill with fluid and expand beyond the second layer 302 in a direction that is distal to the first layer 301. Pressing of the energy absorbing structure 303 or expansion of the reservoirs 308 beyond the second layer 302 may benefit the wearer of the energy absorbing chin protector in multiple ways. First, the pressing of the energy absorbing structure 303 or expansion of the reservoirs 308 past the second layer 302 may allow for the energy absorbing layer to be compressed further than a design without gaps or holes in its second layer and therefore impact severity can be further attenuated. Second, the pressing of the energy absorbing structure 303 or expansion of the reservoirs 308 past the second layer 302 can serve to indicate to coaches, trainers, medical staff, parents, spectators, or other athletes that a severe impact has occurred to the wearer. The energy absorbing structure 303 may be made with a brightly colored material that draws attention or clearly indicates that a severe impact has occurred. Likewise, the reservoirs 308 may be filled with a brightly colored fluid or be designed with a brightly colored exterior that draws attention or clearly indicates that a severe impact has occurred.

[0058] In some embodiments, the pressing of the energy absorbing structure 303 or expansion of the reservoirs 308 past the second layer 302 may be permanent, such that the energy absorbing structure 303 or the reservoirs 308 do not return to their original, pre-impact state after the impact. In some embodiments, the energy absorbing structure 303 or the reservoirs 308 may be returned to their original state by manually resetting them or replacing them. In some embodiments, the energy absorbing structure automatically resets to an undeformed condition after the load has been released. At least a portion of the energy absorbing layer acts as a spring. In these embodiments, the chin protector is ready for another impact nearly immediately after the prior load has been removed.

[0059] Additional materials may be present in the energy absorbing chin protector beyond those described in previous embodiments. FIG. 4A displays a cross-sectional view of an energy absorbing chin protector 400A with support materials. An energy absorbing layer 404 comprised of one or more energy absorbing structures is positioned between a first layer 401 and a second layer 402. Helmet straps 403 may connect the energy absorbing chin protector to a helmet or head protective device. The energy absorbing layer 404 occupies the space between the two layers only partially in some embodiments, while in other embodiments, the space is occupied completely. Surrounding the energy absorbing layer may exist support materials 405. These support materials may make direct contact with a wearer's chin or may be partially or fully covered by the first layer 401. Upon compression, as shown in FIG. 4B, (i.e., the first layer 401 and second layer 402 move nearer to one another), the energy absorbing layer 404 may expand laterally to fill a greater portion of any gap 406 that may exist between and energy absorbing structure and the support materials 405. The support materials may be constructed from a different material than the energy absorbing layer 404, or the same material but at a different density or stiffness. In some embodiments, all of or sections of the support materials may compress to the same extent as the energy absorbing layer during an impact event. In other embodiments, all of or sections of the support materials may compress to a lesser extent than the energy absorbing layer. Common materials for the support materials may include lightweight foams, 3D printed lattice structures, inflatable air bladders, fluid-filled pads, and other materials intended to provide comfort to wearers or absorb impact energy.

[0060] In some embodiments featuring fluid-filled bladders, it may be desirable to have the reservoirs of the fluid-filled bladders affix to or be contained within the helmet straps of the energy absorbing chin protector. FIG. 5 displays an energy absorbing chin protector 500 with reservoirs affixed to its helmet straps. In such embodiments, an energy absorbing layer 503 is displaced between a first layer 501 and a second layer 502. An optional comfort layer 504 may be present in such embodiments for improved comfort when the energy absorbing chin protector is worn on a wearer's chin 507. The energy absorbing layer 503 may be comprised of one or more fluid-filled bladders 508 that are connected to reservoirs 505. When the energy absorbing layer 503 is compressed, the fluid within the fluid-filled bladders 508 will travel into the reservoirs 505. The reservoirs505 may be affixed to the helmet straps 506, such that they do not interfere with compression of the energy absorbing layer 503 and are not as visible as if they were to expand beyond the second layer 502. Furthermore, to reduce visibility of the reservoirs, reservoirs 505 may be contained within the helmet straps 506. In such embodiments, the helmet straps 506 would be designed to fully or partially enclose the reservoirs 505.

[0061] In some embodiments, the energy absorbing chin protector may be contained within a mask. Such masks may be used in sports such as baseball, softball, ice hockey, or others. FIG. 6A displays an example of such a mask 600 containing an energy absorbing chin protector 607. FIG. 6A shows a frontal view of a mask 600 containing an energy absorbing chin protector 607. The mask shell serves as an exterior surface of the mask which may be struck by projectiles, surfaces (e.g., ground, walls, etc.), or other people. The portion of the mask shell that covers the chin and jaw area also serves as a second layer 601 of the energy absorbing chin protector. The mask shell may take the form of a facemask or face cage, constructed from metals such as steel or titanium, or a rigid plastic material. In some embodiments the mask shell may be made from a continuous surface, such as polycarbonate, another plastic material, or a composite material. FIG. 6B shows a cross-sectional view of the energy absorbing chin protector 607 contained within the mask 600. A first layer 602 and the second layer 601 are displaced on either side of an energy absorbing layer 603. An optional comfort layer 605 may be affixed to the first layer 602 in an effort to enhance the wearer's comfort when they wear the mask with the energy absorbing chin protector against their chin 604.

[0062] In other embodiments, the energy absorbing chin protector may be contained within a helmet with a jaw protector integrated to the helmet shell. Such helmets may be used in motorcycle riding, mountain biking, military settings, racecar driving, or other activities. FIG. 7A displays an example of such a helmet 700 containing an energy absorbing chin protector. FIG. 7A shows the helmet 700 with a helmet shell 701 and jaw protector integrated with the helmet shell 701. The jaw protector serves as a second layer 702 for an energy absorbing chin protector 705 and protects the wearer from impacts to the chin or jaw area by the ground, walls, vehicles, objects, other people, or projectiles. FIG. 7B shows a cross-sectional view of the energy absorbing chin protector 705 contained within the helmet 700. A first layer 703 and the second layer 702 are displaced on either side of an energy absorbing layer 704. An optional comfort layer may be affixed to the first layer 703 in an effort to enhance the wearer's comfort when they wear the helmet with the energy absorbing chin protector against their chin 706.

[0063] In some embodiments, the energy absorbing chin protector may not have a second layer. In such embodiments, energy absorption may not fully occur as a result of compression of an energy absorbing layer; rather, energy absorption may occur as a result of stretching of an energy absorbing layer. FIGS. 8A-8C show embodiments of an energy absorbing chin protector without a second layer. FIG. 8A shows an embodiment in which the helmet straps 804 connect directly to an energy absorbing layer 801. Upon direct impact to a facemask, a connected helmet would move backward, forcing a wearer's chin 805 into a comfort layer 803, which would push a first layer 802 forward. The helmet straps 804 would pull on the energy absorbing layer 801 causing it to stretch and absorb energy. FIG. 8B shows an embodiment in which the helmet straps 804 connect directly to an energy absorbing layer 801, but there is no first layer. Similarly, the energy absorbing layer 801 would stretch to absorb energy. In this embodiment, there may be a comfort layer 803. This comfort layer may comprise the same material as the energy absorbing layer 801, but with a different density or texture applied to it. FIG. 8C shows an embodiment in which a helmet strap 804 runs through slots or holes in the energy absorbing layer 801. The helmet strap 804 may hold the energy absorbing layer 801 in a desired position and also pull the energy absorbing layer 801 against a first layer 802. There may be an optional comfort layer 803 in such an embodiment. The helmet strap 804 may also be displaced beyond the energy absorbing layer 801, on its side opposite the first layer 802. In such an embodiment, the energy absorbing layer 801, would compress when the strap pulls towards the wearer's chin.

[0064] FIGS. 9A and 9B show cross-sectional views of an embodiment of an energy absorbing chin protector with a shock absorbing structure displaced between an outer layer and an inner layer. FIG. 9A shows an energy absorbing chin protector 900 with an outer layer 902, an inner layer 904, and a shock absorbing structure 906 displaced between the outer layer 902 and the inner layer 904. The inner layer 904 may be configured to make contact with a wearer's chin when the energy absorbing chin protector 900 is worn or may be fit to an additional layer of material that makes contact with the wearer's chin when worn. The inner layer 904 may be preferably made from a relatively soft material, such as a foam (examples include ethylene-vinyl acetate, vinyl nitrile, polyurethane, proprietary foams like D3O and Poron XRD, etc), a 3D printed lattice material, an air-filled bladder, or a liquid-filled bladder. In some embodiments, the inner layer 904 may be made from a fabric or textile, such as nylon, polyester, or cotton. The inner layer 904 may additionally be configured to be moisture wicking and / or antimicrobial, due to the fact that it may be worn by athletes, military personnel, or workers that may sweat onto the inner layer 904. The inner layer 904 may preferably be between 0.1 mm and 20.0 mm in thickness and may vary in thickness at different sections of it. The shock absorbing structure 906 may occupy all or some of the space between the inner layer 904 and outer layer 902. In cases where the shock absorbing structure 906 does not occupy all of this space, a gap 908 may exist surrounding the shock absorbing structure 906 or between multiple shock absorbing structures 906 if there are a plurality of them. The gap 908 may help in providing ventilation or cooling benefits to a wearer that would otherwise not exist if the space between the inner layer 904 and outer layer 902 were completely filled. However, in some embodiments the volume of space defined by the gap 908 may be filled wholly or partially with one or more optional supports 918. The supports 918 may be fixed to either of the inner layer 904 or the outer layer 902 as shown in FIG. 9B to provide additional comfort to the wearer or improve impact attenuation capabilities. The supports may serve to define the curvature of an inner layer for optimal fit or comfort when worn by a user. To provide ventilation, one or more vents 914 may be located around the outer layer 902. A vent 914 may preferably be between 1 mm2 and 150 mm2 in area. The number of vents 914 in the outer layer 902 may preferably be between zero and twenty. The vents 914 may exist in the outer layer 902 and pass through the inner layer 904 as well. The vents 914 in the inner layer 904 and outer layer 902 may not necessarily align with one another in shape, size, or location. In addition, one or more strap vents 912 may be present in the outer layer 902. A strap vent 912 would be sized such that a strap 910 can easily slide through it. The strap vent 912 may preferably be between 10 mm2 and 80 mm2. A strap 910 may preferably be between 1 mm and 4 mm in thickness, between 10 mm and 20 mm in width. A strap 910 may be able to slide freely through a strap vent 912 entirely throughout its length or may be restricted to slide only along a desired amount of its length.

[0065] The various components of the energy absorbing chin protector 900 may be affixed to one another in various ways. In a preferred embodiment, the inner layer 904 may be affixed to the outer layer 902 along the entirety or a portion of the outer edge of the outer layer 902. The means of affixing the inner layer 904 and outer layer 902 may preferably be with a glue or adhesive. In some embodiments, it may be preferable to affix the inner layer 904 and outer layer 902 at mounting zones 916. The mounting zones 916 may be raised surfaces coming off the inner surface of the outer layer 902 that rise up to meet the inner layer 904. A glue or adhesive may be applied to a mounting zone 916 that contacts the inner layer 904, or the mounting zone 916 may wholly or partially pierce through the inner layer 904. Furthermore, the inner layer 904 may directly affix to the shock absorbing structure 906 with glue, adhesive, or stitching. The shock absorbing structure may additionally affix to the outer layer 902.

[0066] FIG. 9B shows the energy absorbing chin protector when the shock absorbing structure 906 has been compressed, such as it would during an impact. Furthermore, the inner layer 904 may stretch as the shock absorbing structure 906 compresses. The stretching of the inner layer 904 materials may serve to absorb additional energy that is not absorbed due to compression of the shock absorbing structure 906.

[0067] FIG. 10A is a view of the energy absorbing chin protector's exterior. The energy absorbing chin protector 1000 has an outer layer 1002 that is mated to an inner layer 1004. The outer layer 1002 has at least one vent 1014 in it, which may serve a purpose targeted towards aesthetics or ventilation. The outer layer 1002 may also have a strap vents 1012 in its design, through which straps 1010 may slide.

[0068] FIG. 10B is an interior view of the energy absorbing chin protector 1000 with its inner layer removed. On the interior surface of the outer layer 1002, a shock absorbing structure 1006 is placed. The shock absorbing structure 1006 does not take up all of the space in the interior surface of the outer layer 1002 and there may be one or more gaps 1008 surrounding it. The shock absorbing structure 1006 could potentially cover, partially or completely, one or more of the vents 1014 in the outer layer 1002. Several mounting zones 1016 can be found around the edge of the outer layer 1002 for potential mounting to an inner layer. In some embodiments, parts or all of the outer layer 1002 may be made transparent or translucent, such that a wearer or spectator can visualize the internal components of the energy absorbing chin protector without requiring disassembly. This may serve an aesthetic benefit but may also serve a safety benefit by allowing sight into the device to see if an energy absorbing structure 1006 has failed or requires maintenance. A visual indicator indicative of the operating condition shock absorbing structure 1006 is provided. For example, a failure may be indicated if fluid escapes the shock absorbing structure 1006. A visual indicator may involve the internal fluid being dyed a certain color, such that if a substantial amount of the dyed fluid is visible, it would indicate the shock absorbing structure has failed or be permanently compressed Furthermore, a transparent or translucent section of the outer layer may allow for visualization of a shock absorber that may indicate a severe impact has occurred, thus enabling a coach, trainer, spectator, medical staff member, or the wearer themselves to take preventative or diagnostic action. This would enable a more rapid decision to assess a wearer for potential injury.

[0069] FIG. 11 shows data from impact testing to the facemask of a helmet while different chinstraps are being worn. In these tests, a 3.0 m / s impact has been delivered by a pneumatic linear impactor to the facemask of an American football helmet that has been mounted onto an anthropomorphic test headform. In this case, the headform is a size medium NOCSAE headform mounted to a 50th percentile male Hybrid III neckform. The base of the neckform is affixed to a sliding carriage that allows the head-neck system to slide freely along rails upon an applied force to the head. The location of the impact on the facemask is the Facemask Central Oblique location described in the National Football League's publicly available Helmet Test Protocol. In each test, the helmet is equipped with a chinstrap, as is required for use in American football. A triaxial array of accelerometers and gyroscopes are mounted at the center of gravity of the headform to measure the linear and rotational motion of the head during an impact event. These measurements can be used to calculate various brain injury risk criteria, such as the Head Acceleration Response Metric (HARM), which is used by the National Football League in their assessment of helmets for impact safety. A greater HARM value caused by an impact would indicate a greater risk of sustaining a concussion from the impact, and, therefore, manufacturers of helmets seek to reduce the value of HARM during impacts by engineering the helmet and its components to reduce linear and rotational motion of the head during an impact event. During an impact to the facemask, the helmet is pushed backwards in relation to the test headform, and the chinstrap is put into tension as it presses against the chin of the headform. The chin of the headform may apply a force to the inner surface of the chinstrap during the impact event, and reduction of said force has the potential to reduce the linear and rotational motion of the head due to the impact to the facemask. The graph shown in FIG. 11 demonstrates results from impact testing to the Facemask Central Oblique location of a Riddell Speedflex helmet. The difference in HARM values across 14 different chinstraps being equipped to the helmet is shown, each bar representing a different chinstrap on the same helmet, one of which is an embodiment of an energy absorbing chin protector. Each bar represents an average of 10 identical impact trials. The bar marked S (HARM=2.62) represents a commonly used “soft cup” chinstrap for American football helmets that is made entirely of a single layer of leather / faux leather material (Riddell Soft Cup Chinstrap). The bars marked with an H (H1 to H12) represent 12 commercially available “hard cup” chinstraps that have a rigid outer layer (an outer shell made typically of polycarbonate or acrylonitrile butadiene styrene) and an inner layer for comfort. Bar H1 (HARM=2.45) represents a chinstrap with a rigid outer layer and a comfort foam liner (Shock Doctor Showtime Chinstrap). Bar H2 (HARM=2.39) represents a chinstrap with a polycarbonate outer layer with medical grade comfort foam liner and comfort gel / liquid pad that contacts a wearer's chin (SportStar Victory T-Rex Hurricane Gel Chinstrap). Bar H3 (HARM=2.39) represents a chinstrap with a polycarbonate outer layer with medical grade comfort foam liner (SportStar X-1 T-Rex Hurricane Chinstrap). Bar H4 (HARM=2.35) represents a chinstrap with a rigid outer layer and a comfort foam liner (Schutt Fusion Chinstrap). Bar H5 (HARM=2.27) represents a chinstrap with a polycarbonate outer layer and a comfort foam liner (Riddell TCP Chinstrap). Bar H6 (HARM=2.27) represents a chinstrap with a rigid outer layer with deformable upper panel and a comfort foam liner (Schutt Fusion Elite Chinstrap). Bar H7 (HARM=2.26) represents a chinstrap with a rigid outer layer and an EVA comfort foam layer (Battle Sports Chinstrap). Bar H8 (HARM=2.23) represents a chinstrap with a rigid outer layer with deformable upper panel and a comfort foam liner (VICIS Fusion Elite Chinstrap). Bar H9 (HARM=2.19) represents a chinstrap with a polycarbonate outer layer and a comfort foam liner (Riddell Hard Cup Chinstrap). Bar H10 (HARM=2.15) represents a chinstrap with a polycarbonate outer layer with a medical grade comfort foam liner and comfort gel / liquid pad with extending fingers which contacts a wearer's chin (SportStar X1 GX-4 Chinstrap). Bar H11 (HARM=2.14) represents a chinstrap with a rigid outer layer and a comfort foam liner (VICIS Fusion Chinstrap). Bar H12 (HARM=2.13) represents a chinstrap with a rigid nylon outer layer and an EVA comfort pad liner (Under Armour Spotlight Chinstrap). As noted, none of the commercially available “hard cup” chinstraps tested contain an energy absorbing layer, though each has a compliant foam material included. The bar marked E (HARM=1.59) represents an energy absorbing chin protector, which has a rigid outer layer made of polycarbonate, an inner layer made of ethylene-vinyl acetate foam, and an inner shock absorbing structure (i.e., as part of an energy absorbing layer) disposed between the inner layer (i.e, first layer) and outer layer (i.e., second layer). As shown, the energy absorbing chin protector results in a HARM value of 25-40% lower than all of the other 13 commercially available chinstraps. It is evident from this data that inclusion of a shock absorbing structure or energy absorbing layer disposed between an outer layer (or “second layer”) and an inner layer (or “first layer”) can dramatically improve safety for impacts to the facemask of an American football helmet. It is likely that other shock absorbing structures could further improve the ability to reduce HARM values and other brain injury risk metrics. It should be noted that the introduction of a hard shell and a comfort foam liner consistently reduced the HARM metric compared to the soft cup chinstrap, regardless of outer layer or inner layer material, but not nearly as great of a reduction as the energy absorbing chin protector. It should also be noted that the shock absorbing structure utilized in the energy absorbing chin protector represented by bar E is a fluid filled bladder in connection with a reservoir (such as those shown in FIGS. 9A / 9B, 10B, 12, 13A / 13B, 14, 15, and 16); use of fluid or gel filled bladders that make direct contact with the chin and do not have orifices or reservoirs (such as those utilized in chinstraps represented by bars H2 or H10, which are targeted towards increasing comfort) are insufficient to substantially differentiate from other “hard cup” designs in the reduction of the HARM metric.BarAverage HARM% Difference from ES2.6239.3%H12.4535.1%H22.3933.6%H32.3933.5%H42.3532.2%H52.2730.0%H62.2729.9%H72.2629.6%H82.2328.6%H92.1927.5%H102.1526.1%H112.1425.7%H122.1325.4%E1.590.0%

[0070] FIG. 12 shows an example chin protector 1200 including an outer layer 1203 containing a shock absorbing structure 1202 and supports 1201. Supports 1201 are designed to be approximately the same height as the shock absorbing structure 1202, such that an inner layer could be assembled by directly contacting each of the supports 1201 and shock absorbing structure 1202 when in an uncompressed state.

[0071] FIGS. 13A and 13B provide an example of an energy absorbing chin protector 1300 with a transparent section 1302 of its outer layer 1301. FIG. 13A shows a front view of the energy absorbing chin protector 1300 with outer layer 1301 including transparent section 1302. FIG. 13B shows an isometric view of energy absorbing chin protector 1300 with outer layer 1301 and transparent section 1302. Transparent section 1302 provides visibility to a shock absorbing structure 1303. In some embodiments, the shock absorbing structure 1303 may be a fluid-filled bladder.

[0072] FIGS. 14-16 depict another alternate embodiment chin protector identified at reference numeral 1400. Chin protector 1400 is substantially similar to chin protector 900. Some or all of the features described in relation to chin protector 900 may also be implemented in relation to chin protector 1400. Accordingly, portions of the description will not be repeated to avoid redundancy.

[0073] Chin protector 1400 includes a compliant first layer or inner layer 1404, a rigid second layer or outer layer 1402, and a shock absorbing structure 1406 otherwise known as an energy absorbing layer disposed between outer layer 1402 and inner layer 1404. Inner layer 1404 includes a central panel 1408 with an integrally formed flange 1410 circumscribing central panel 1408. Inner layer 1404 includes a first surface 1412 and an opposite second surface 1414. First surface 1412 is positioned in contact with or proximate a wearer's chin. A plurality of bumpers 1416 are integrally formed with inner layer 1404 and protrude from first surface 1412. Each bumper 1416 includes a land 1418 configured to contact a wearer's chin firstly upon initial installation of chin protector 1400 to the wearer. Bumpers 1416 are deformable to provide a comfortable fit to the wearer regardless of the exact anatomical profile of the chin.

[0074] Inner layer 1404 includes a pressure pad 1420 interconnected to central panel 1408 by a living hinge 1422. Based on the position and orientation of living hinge 1422, pressure pad 1420 may translate along a central axis 1423 when acted upon by a force. Apertures 1424 extend through central panel 1408 at diametrically opposed positions adjacent pressure pad 1420. Apertures 1424 provide ventilation and aid in providing a degree of freedom facilitating the function of living hinge 1422 to allow axial translation of pressure pad 1420. As best shown in FIG. 14 and on the opposite side of inner layer 1404, first through fourth supports 1426, 1427, 1428, 1429, respectively, outwardly protrude from second surface 1414. In some embodiments, first, second, third, and fourth supports 1426, 1427, 1428, and 1429, respectively, may be connected to one another, forming a ring around shock absorbing structure 1406. Additional apertures 1432 extend through inner layer 1404 for ventilation.

[0075] Outer layer 1402 includes a body 1440 and a panel 1442 fixed thereto. In one exemplary embodiment, body 1440 is constructed from a first substantially rigid material such as previously described in relation to second layer 202. Panel 1442 may be constructed from a similar material but is preferably clear or translucent to act as a window allowing an observer to view shock absorbing structure 1406 while chin protector 1400 is attached to a wearer. In some embodiments, panel 1442 may also be an alternate color from body 1440, which may function to identify different athletes, player positions, teams, or the like from one another in training or competition This may be useful in coordinating practice routines, identifying individuals as “non-contact” for practices if they are returning from injury, or to differentiate teams from one another during a competition.

[0076] In one embodiment, panel 1442 may be constructed from a transparent polycarbonate material. In one method of manufacturing chin protector 1400, body 1440 may be injected molded during a “first shot” of a first material into a mold. During a “second shot” of a different material within the same mold, panel 1442 may be formed and fixed to the body 1440 such that no additional adhesives or fasteners are required. In an alternate manufacturing arrangement, body 1440 may be individually molded and constructed separately from panel 1442. Panel 1442 is then positioned within a central aperture 1446 extending through body 1440 and mounted to body 1440 using any number of suitable processes including plastic welding, adhesive bonding, or mechanical interconnection such as slots and tabs. Panel 1442 includes a first edge 1443 and an opposite second edge 1445. First edge 1443 and second edge 1445 are spaced apart from body 1440 such that gaps 1447 and 1449 are formed between panel 1442 and body 1440. In some embodiments, panel 1442 may be removable and interchanged with another panel 1442 of a different color or shape, according to the wearer's preference or need for identification by coaches, training staff, or competition officials.

[0077] Outer layer 1402 includes an outer surface 1448 and an opposite inner surface 1450. Outer layer 1402 includes a plurality of apertures 1452 extending therethrough. Apertures 1452 and other apertures not particularly identified may function as passageways for portions of straps 1434 or may simply provide ventilation. Straps 1434 may be received by multiple apertures such that they cannot slide freely during use and remain relatively fixed in place after assembly. A recess 1454 is formed on inner surface 1450 or more particularly an inner surface 1456 of panel 1442. Recess 1454 is sized and shaped to receive shock absorbing structure 1406 in both uncompressed and compressed modes of operation.

[0078] Shock absorbing structure 1406 includes a bladder 1462 and a reservoir 1464. In the embodiment depicted in the figures, bladder 1462 is a compliant component that is movable from an unloaded position depicted in the figures to a collapsed or loaded position (FIG. 9B). In embodiments featuring a fluid filled bladder 1462 in communication with a reservoir 1464, a spring force may be provided by the bladder 1462. Thus, during compression the bladder collapses and fluid flows from the bladder into the reservoir. Upon removal of a compressive load the spring-like behavior of the bladder enables the bladder to return to its uncompressed, unloaded state and for fluid to flow back into the bladder from the reservoir. While bladder 1462 may be compliant to move or deform in a direction that is axial to an impact force, in some embodiments it may partially or wholly resist circumferential expansion caused by increasing fluid pressure during compression. Bladder 1462 may be constructed from any number of materials suitable to retain a fluid therein and repeatedly move from the undeformed position to the collapsed position and back again. In at least one embodiment, bladder 1462 is constructed from a material that returns to its undeformed state after the load is removed. The shape of bladder 1462 also assists in allowing the bladder to collapse under load and return to an undeformed state as shown in FIG. 16 after the load is removed.

[0079] Reservoir 1464 includes two components fixed to one another in the embodiment shown in the figures. A frustoconically shaped shroud 1466 circumscribes bladder 1462. A base 1468 may be constructed from the same material as shroud 1466 or a different material. Base 1468 is positioned in engagement with a bottom surface 1470 of bladder 1462 and sealing coupled to both shroud 1466 and bottom surface 1470. Bladder 1462 includes a plurality of orifices 1472 providing passageways for fluid communication between an interior volume 1474 of bladder 1462 and an interior volume 1478 of reservoir 1464. When bladder 1462 is in the unloaded and uncompressed position depicted in FIG. 16, interior volume 1474 is filled with a fluid such as oil, water, propylene glycol, or air. At this time, minimal fluid is positioned within interior volume 1478 of reservoir 1464. Upon receipt of an impact to the helmet or chin strap, shock absorbing structure 1406 may dissipate the impact energy by collapsing bladder 1462 and transferring fluid from interior volume 1474 of bladder 1462 to interior volume 1478 of reservoir 1464. Shroud 1466 is constructed from an elastomeric material such that the shape of reservoir 1464 in the uncompressed and unloaded condition may be significantly different than the shape of shroud 1466 when shock absorbing structure 1406 is in the compressed position. Recess 1454 is sized to accept a radially enlarged shape of shroud 1466 when shock absorbing structure 1406 is compressed.

[0080] Base 1468 may be fixed to pressure pad 1420 by an adhesive or other attachment mechanism. Reservoir 1464 includes an outer surface 1482 having a planar portion 1484 in an engagement with a surface 1486 of recess 1454. In at least one embodiment, planar portion 1484 and surface 1486 are not fixed to one another but arranged in a sliding or slip fit interconnection. By avoiding the use of adhesive at this joint, a clear view of the shock absorbing structure 1406 through translucent panel 1442 remains after assembly of the components of chin protector 1400.

[0081] As best shown in FIG. 16, a majority of inner layer 1404 is spaced apart from outer layer 1402. First support 1426 includes an engagement surface 1490 spaced apart from inner surface 1450 of outer layer 1402 a predetermined distance. This predetermined distance is less than a distance between central panel 1408 and outer layer 1402 at positions other than first support 1426 and second support 1428. The reduced spacing between first support 1426 and inner surface 1450 as well the spacing between second support 1428 and inner surface 1450 provides a guiding or form-fitting function to accommodate a wide variety of anatomical shapes of chins. First support 1426 and second support 1428 are integrally formed with inner layer 1404 and constructed from a compliant material such as foam that locally compresses to conform to the user's anatomical features as necessary. It should be appreciated that first and second supports 1426, 1428 may alternatively be constructed as separate components and not integrally formed with inner layer 1404. An example of such can be seen in the supports 1201 coupled to the outer layer 1203 in FIG. 12.

[0082] The supports 1426-1429 may include a different stiffness or density than the remainder of inner layer 1404 or each other. For example, some or all the supports may be softer and more compressible to provide for a more relaxed fit and less interaction of the shock absorbing structure 1406 during compressive loading. Alternatively, some of the supports may be stiffer than the remainder of inner layer 1404 or each other to provide additional energy absorption during impact.

[0083] Making an energy absorbing layer that attenuates enough energy to sufficiently reduce metrics like HARM, head accelerations, or peak forces would require the energy absorbing layer to be sufficiently stiff, such that it may be uncomfortable to wear directly against the chin, or may not conform adequately to different chin shapes. In sports such as American football, lacrosse, or ice hockey, for example, impact velocities range from 1.5 m / s to 11.0 m / s, and impact energies range from 5 to 950 J, roughly. Projectiles can be launched at a facemask at upwards of 120 mph as well. In order to attenuate impacts of these energies, a material would need to be stiff enough to avoid bottoming out, otherwise risking a sharp rise in impact forces. Materials of the energy absorbing layer may be tuned to attenuate a narrow range of energies specifically targeted within this wide range, or the whole range. In embodiments where the energy absorbing layer contains one or more fluid-filled bladders, the bladders may contain rigid components or have uncomfortable edges or surfaces. In embodiments where the energy absorbing layer contains foams or lattice structures, the stiffness of these materials may be high enough such that they do not compress and form to the wearer's chin in order to avoid bottom out upon impact, thus creating high pressure points and poor fit to the chin. Therefore, utilizing a compliant first layer of a lower stiffness than the energy absorbing layer enables the chin protector to meet both comfort and fit functionality as well as provide protection for relevant impact energies.

[0084] The various components of an energy absorbing chin protector may affix to one another in several ways. In some embodiments, an adhesive may be used to affix the energy absorbing layer to the first layer and / or the second layer. In other embodiments, a screw or rivet may pass through the energy absorbing layer and the first layer and / or the second layer. In other embodiments, the comfort layer, first layer, energy absorbing layer, and / or the second layer may affix to each other with Velcro or double-sided tape. In other embodiments, the first layer and second layer may affix to one another while the energy absorbing layer is displaced loosely between them without being permanently affixed to either. The comfort layer may affix to the first layer with an adhesive or rivet. In some embodiments, the comfort layer may be comprised of the same, continuous material as the first layer, but with a different finish, texture, or stiffness. In other embodiments, the energy absorbing layer may be comprised of the same, continuous material as the first layer, but with a different finish, texture, or stiffness. The helmet straps may be connected to the second layer through holes or slots in the second layer, or they may be stitched to the second layer, first layer, or energy absorbing layer.

[0085] In some embodiments, the straps which connect to the helmet would attach to the layer further from the wearer's chin and past the energy absorbing layer, deemed the second layer. In this embodiment, upon impact the wearer's chin would compress the comfort layer which would cause the first layer, assuming it is sufficiently rigid, to compress the energy absorbing layer such that this layer reduces the impact effect on the wearer's head. In some embodiments, the energy absorbing layer would expand laterally during impact into the space between the first layer and the second layer. In another embodiment, the energy absorbing layer would protrude through the second layer in response to an impact. In another embodiment, the energy absorbing layer would compress to an external area of the chin strap between the first layer and second layer such as towards the straps.

[0086] In some embodiments, the straps which connect to the helmet would attach directly to the energy absorbing layer. In this embodiment, there may or may not be a second layer. The direct connection to the energy absorbing layer could better cushion the wearer's head from any impact to the helmet by directly connecting the helmet shell via the straps to the energy absorbing layer. In this embodiment the chin strap may connect to each end of the energy absorbing layer and stretch the energy absorbing layer during impact. The chin strap may also feed through the energy absorbing layer through an inner cavity or channel which would allow it to be one continuous strap that connects to each side of the helmet instead of two distinct straps. In this embodiment, the ability to pass the strap directly through may provide performance benefits. In addition, the single strap mechanism may enable the helmet to be easier to fit to individual wearer's heads.

[0087] It may be desirable for an energy absorbing chin protector to be customized for a specific wearer's chin. In such embodiments, the shape and size of the comfort layer, first layer, and / or the energy absorbing layer may be customized according to the geometry of the wearer's chin. This can be achieved by first 3D scanning a wearer's chin and / or jaw region. Then if 3D printed materials are being used for any of the comfort layer, energy absorbing layer, or first layer (or its supports), they may be printed according to a geometry that would provide optimal comfort or impact attenuation. An alternative embodiment could involve placing shims in the chin protector to appropriately fit the chin protector to the jaw area. Another embodiment could involve obtaining comfort layers, first layers, and / or energy absorbing layers or various sizes, shapes, or densities and choosing the size most appropriate for a specific wearer's comfort or impact attenuation needs.

[0088] In some embodiments, a wearer or helmet owner may want to improve the performance of an existing chinstrap or chin protector that they already possess. In such cases, an embodiment of the energy absorbing chin protector may exist such that it is able to be retrofitted to an existing chinstrap or chin protector. In this case, an energy absorbing layer may be integrated into a sleeve that the chinstrap or chin protector can be fed through such that it fits over it. In this embodiment, the sleeve may contain a comfort layer and a first layer in front of the energy absorbing layer such that when the wearer's chin moves forward it presses against the first layer or comfort layer. In this embodiment, the chinstrap or chin protector that is already possessed may act as the second layer to which the energy absorbing chin protector may be affixed. In another embodiment where the wearer or helmet owner would like to improve the performance of a chin protector of the structure typical in motorcycle riding, mountain biking, military settings, race car driving, baseball, softball, ice hockey, or similar, an embodiment of the energy absorbing chin protector may be integrated into a pad that can be affixed to the existing chin cup via an adhesion method such as Velcro, glue, stitching, rivets, or similar.

[0089] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

1. A device intended to be worn over the chin of a wearer, comprising:a compliant first layer;a rigid second layer coupled to the first layer and displaced farther from the wearer than the first layer; andan energy absorbing layer positioned between the first layer and second layer,wherein the first layer and second layer are moveable toward one another, the energy absorbing layer being operable to dissipate a transfer of energy between the first layer and the second layer.

2. The device according to claim 1, wherein the energy absorbing layer includes a first zone including a first stiffness and a second zone spaced apart from the first zone and including a second stiffness less than the first stiffness.

3. The device of claim 1, wherein the first zone includes a shock absorber and the second zone includes a support.

4. The device of claim 3, wherein the shock absorber includes a first surface contacting the first layer and a second surface contacting the second layer.

5. The device of claim 4, wherein the support includes a first surface protruding from one of the first layer and the second layer.

6. The device of claim 5, further comprising another support protruding from the one of the first layer and the second layer and diametrically opposed to the support on the opposite side of the shock absorber.

7. The device of claim 1, wherein the rigid second layer includes a translucent portion proximate the energy absorbing layer.

8. The device of claim 1, wherein the energy absorbing layer includes a fluid filled bladder in communication with a reservoir, wherein the fluid is transferred between the bladder and the reservoir when the first layer and the second layers move toward one another.

9. The device of claim 1, wherein the energy absorbing layer includes a visual indicator operable to indicate that the energy absorbing layer is inoperable.

10. The device of claim 7, wherein the translucent portion is shaped as a panel separate from a remainder of the second layer.

11. The device of claim 2, wherein the second zone includes an air gap.

12. The device of claim 1, wherein the energy absorbing layer comprises a different material than the first layer.

13. The device of claim 1, wherein the device is configured to be connected to a helmet.

14. The device according to claim 1, wherein the device exhibits a Head Acceleration Response Metric (HARM) less than or equal to 2.1, wherein the HARM is determined by an impact test including a 3.0 m / s impact delivered by a pneumatic linear impactor to a facemask of a helmet coupled to the device that has been mounted to an anthropomorphic test headform, wherein the headform is a size medium NOCSAE headform mounted to a 50th percentile male Hybrid III neckform.

15. The device according to claim 1, wherein the energy absorbing layer has a greater stiffness than the first layer.

16. A device intended to be worn over the chin of a wearer, comprising:a compliant first layer;a rigid second layer coupled to the first layer and displaced farther from the wearer than the first layer; andan energy absorbing layer positioned between the first layer and second layer,wherein the second layer includes a translucent portion providing a line of sight to the energy absorbing layer.

17. The device according to claim 16, wherein the energy absorbing layer includes a visual indicator operable to indicate a status of the energy absorbing layer.

18. The device of claim 17, wherein the visual indicator is positioned within a field of view through the translucent portion.

19. The device according to claim 16, wherein the device exhibits a Head Acceleration Response Metric (HARM) less than or equal to 2.1, wherein the HARM is determined by an impact test including a 3.0 m / s impact delivered by a pneumatic linear impactor to a facemask of a helmet coupled to the device that has been mounted to an anthropomorphic test headform, wherein the headform is a size medium NOCSAE headform mounted to a 50th percentile male Hybrid III neckform.

20. A device intended to be worn over the chin of a wearer, comprising:a first layer;a rigid second layer displaced farther from the wearer than the first layer; andan energy absorbing layer positioned between the first layer and second layer,wherein the energy absorbing layer includes a fluid filled bladder in communication with a reservoir.

21. The device of claim 20, wherein the device is configured to be attached to a helmet.

Images