Helmet impact liner

Abstract

A helmet impact liner includes an impact pad having an exterior surface configured to be removably coupled to an interior surface of a helmet. An interior surface of the impact pad is opposite the exterior surface. The helmet impact liner includes a cushion pad having a cushion pad body, an exterior surface removably coupled to the interior surface of the impact pad, an interior surface opposite the exterior surface, and a coupling tab extending from the cushion pad body and coupled to the exterior surface of the impact pad.

Description

TITLE

[0001] Helmet Impact LinerCROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 607,521 filed December 7, 2024 entitled “Helmet Impact Liner”, which is incorporated by reference herein in its entirety.TECHNICAL FIELD

[0003] The present disclosure generally relates to helmet impact liners and, in some embodiments, to repositionable impact pads and cushion pads of helmet impact liners.SUMMARY

[0004] In one embodiment, there is a helmet impact liner including an impact pad having an exterior surface configured to be removably coupled to an interior surface of a helmet, and an interior surface opposite the exterior surface, and a cushion pad having a cushion pad body, an exterior surface removably coupled to the interior surface of the impact pad, an interior surface opposite the exterior surface, and a coupling tab extending from the cushion pad body and coupled to the exterior surface of the impact pad.

[0005] In some embodiments, the impact pad comprises a plurality of impact pads configured to be spaced from one another when coupled to the interior surface of the helmet. In some embodiments, the impact pad comprises five impact pads. In some embodiments, the impact pad further includes an impact pad depression defined on the exterior surface thereof, the impact pad depression located at a central portion of the impact pad and abutting a bottom end of the impact pad, and the impact pad depression includes a first fastener.

[0006] In some embodiments, the coupling tab extends around the bottom end of the impact pad and couples to the first fastener of the impact pad depression. In some embodiments, engagement of the coupling tab and the impact pad depression couples the cushion pad to the impact pad. In some embodiments, the coupling tab comprises a coupling area defined on an end opposite the cushion pad body, the coupling area comprising a second fastener configured to removably couple to the first fastener. In some embodiments, the coupling area and the impact pad depression are a common size and shape. In some embodiments, the first fastener and the second fastener are hook-and-loop fasteners. In some embodiments, the cushion pad comprises a plurality of cushion pads configuredto be spaced from one another when coupled to the interior surface of the impact pad. In some embodiments, the impact pad has a first density and the cushion pad has a second density, and wherein the first density is higher than the second density.

[0007] In another embodiment, there is a helmet including a helmet shell having an inner surface, an impact pad having an exterior surface removably coupled to the inner surface of the helmet, and an interior surface opposite the exterior surface, and a cushion pad having a cushion pad body, an exterior surface removably coupled to the interior surface of the impact pad, an interior surface opposite the exterior surface, and a coupling tab extending from the cushion pad body and coupled to the exterior surface of the impact pad.

[0008] In some embodiments, the impact pad comprises five impact pads positioned on the inner surface of the helmet. In some embodiments, an edge of each of the five impact pads is between about 8 mm to about 40 mm from an edge of an adjacent impact pad when positioned on the inner surface of the helmet. In some embodiments, the impact pad further includes an impact pad depression defined on the exterior surface thereof, the impact pad depression located at a central portion of the impact pad and abutting a bottom end of the impact pad, and the impact pad depression includes a first fastener. In some embodiments, the coupling tab extends around the bottom end of the impact pad and couples to the first fastener of the impact pad depression.

[0009] In another embodiment, there is a helmet including a helmet shell having an inner surface, a plurality of impact pads, each having an exterior surface removably coupled to the inner surface of the helmet, an interior surface opposite the exterior surface, and an impact pad depression defined on the exterior surface of at least one of the plurality of impact pads, the impact pad depression abutting a bottom end of the impact pad and including a first fastener, and a plurality of cushion pads, each having a cushion pad body, an exterior surface removably coupled to the interior surface of the impact pad, an interior surface opposite the exterior surface, and a coupling tab extending from the cushion pad body and coupled to the exterior surface of the impact pad, at least one of the plurality of impact pads having a chamfered edge at the exterior surface thereof facing towards the inner surface of the helmet shell, and the coupling tab extends around the bottom end of the impact pad and couples to the first fastener of the impact pad depression.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The following detailed description of embodiments of the helmet impact liner, will be better understood when read in conjunction with the appended drawings of exemplary embodiments.It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.

[0011] In the drawings:

[0012] Fig. 1 is a front bottom perspective view of the helmet impact liner coupled to a helmet in accordance with an exemplary embodiment of the present invention;

[0013] Fig. 2A is a front top perspective view of a helmet impact liner of Fig. 1 coupled to a helmet shell with mounting features omitted in accordance with an exemplary embodiment of the present invention;

[0014] Fig. 2B is a front top perspective view of the helmet impact liner of Fig. 2A with the helmet shell omitted;

[0015] Fig. 3 is a rear side perspective view of the helmet impact liner of Fig. 2A;

[0016] Fig. 4 is a rear bottom perspective view of the impact pads of the helmet impact liner ofFig. 1A;

[0017] Fig. 5 is a partial bottom view of a front impact pad of the helmet impact liner of Fig. 2A disposed in a helmet;

[0018] Fig. 6 is a bottom view of the helmet impact liner of Fig. 2A disposed in a helmet;

[0019] Fig. 7A is a top view of a front cushion pad of the helmet impact liner of Fig. 2A;

[0020] Fig. 7B is a top view of a central cushion pad of the helmet impact liner of Fig. 2A;

[0021] Fig. 7C is a top view of a rear cushion pad of the helmet impact liner of Fig. 2A;

[0022] Fig. 8 is a rear perspective view of the helmet impact liner of Fig. 2A;

[0023] Fig. 9 is a front perspective view of a helmet impact liner in accordance with another exemplary embodiment of the present disclosure coupled to a helmet shell with mounting features omitted; and

[0024] Fig. 10 is a front perspective view of the helmet impact liner of Fig. 9.DETAILED DESCRIPTION

[0025] Helmets for head protection are worn in a variety of environments and for various purposes. The primary purpose of a helmet is to mitigate the effects of impact on the user’s head. Helmets are meticulously designed to absorb and dissipate the force generated by ballistic threats, explosions, or other high-velocity projectiles. Helmets used in military applications are designed to provide comprehensive protection against various threats, including ballistic, blunt, and blast impacts. The incorporation of advanced materials, such as aramid fibers or ceramic plates, enhances the helmet’s ability to withstand and disperse the impact energy, reducing the risk of traumatic headinjuries in the field. Moreover, these helmets often feature elements that address specific military needs, such as compatibility with communication systems, night vision devices, and camouflage.

[0026] In helmet design, the integration of effective impact attenuation and interior padding is essential to provide comprehensive protection against a wide range of threats. The combination of advanced materials, innovative design, and a focus on user comfort ensures that military helmets meet the stringent requirements of modern warfare while prioritizing the safety and well-being of the wearer.

[0027] Referring to the drawings in detail, wherein like reference numerals indicate like elements throughout, there is shown in Figs. 1-8 a helmet impact liner, generally designated 100, in accordance with an exemplary embodiment of the present invention. In some embodiments, the helmet impact liner 100 is configured to improve retention of the cushion pad on the impact pad and reduce movement of the cushion pad relative to the impact pad. In some embodiments, the reduction of movement of the cushion pad relative to the impact pad reduces irritation and increases comfort for a wearer during prolonged use. In some embodiments, the helmet impact liner 100 includes a plurality of impact and cushion pads positioned relative to each other such that the helmet impact liner 100 may fit to a plurality of differently sized helmets. Single piece liners often cannot fit in more than one sized helmet.

[0028] Referring to Figs. 1-2B, there is shown a helmet impact liner 100 configured to be coupled to an interior surface 110 of a helmet 102. In Fig. 2A, the portions of the helmet impact liner 100 obscured by the helmet 102 are depicted in broken lines. In Fig. 2 A one or more fasteners and / or mounting features (e.g., accessory rail mounts, shroud mounts) have been omitted for illustration purposes. The helmet 102 may be a helmet shell for use in a variety of environments and for various purposes including, but not limited to, adventure activities, sporting, industrial safety, and police or military purposes. In some embodiments, the helmet 102 may be any type of head protection helmet shell known in the art. For example, helmet 102 may be included in a standard infantry ballistic helmet, an advanced combat helmet (ACH) an enhanced combat helmet (ECH), a modular integrated communications helmet (MICH), a tactical ballistic helmet (TBH), a lightweight marine helmet, a police general duty helmet, a personnel armor system for ground troops (PASGT), or an aircrew helmet, such as an HGU-56 / P rotary wing helmet or an HGU 55 / P fixed wing helmet.

[0029] In some embodiments, the helmet 102 is formed of a substrate generally made of a fiber / resin-based ballistic material. It can be rigid, flexible, or partly rigid and partly flexible. In some embodiments, the substrate or a portion of the substrate is made of a material including ultra- high molecular-weight polyethylene (UHMWPE), poly-p-phenylene terephthalamide, aramid, or thelike, or any combination thereof. The substrate can be of a single layer or a stack or layup of a composite structure including a plurality of layers / plies of one or more materials. For instance, in an embodiment, the substrate includes a single UHMWPE ply. In some embodiments, the helmet 102 has a thickness as measured between the exterior surface 109 and interior surface 110 between about 0.4 inches to about 1.0 inches. In some embodiments, the helmet 102 has a thickness as measured between exterior surface 109 and interior surface 110 between about 0.4 inches to about 0.8 inches. In some embodiments, the thickness of the helmet 102 is about 0.76 inches. In some embodiments, the thickness of the helmet 102 is about 0.40 inches. In some embodiments, the thickness of the helmet 102 is about 0.28 inches.

[0030] As described in more detail below, the helmet impact liner 100 may include one or more impact pads 104 and one or more cushion pads 118. The one or more impact pads 104 may provide shock absorption and protective functionality between the helmet 102 and the user. The one or more cushion pads 118 may provide a customized fit between the helmet 102 and the user’s head to improve wearability and comfort. Each of the impact pads 104 may have an exterior surface 106 configured to be removably coupled to an interior surface 110 of the helmet 102. The interior surface 108 may be on an opposite side of the impact pad 104 from the exterior surface 106. The helmet impact liner 100 may include one or more cushion pads 118 removably coupled to the impact pads 104.

[0031] Referring to Figs. 2A-5, the helmet impact liner 100 may include an impact pad 104.The impact pad 104 may provide features such as, but not limited to, shock absorption, customized fit, rotational force management, comfort, multi-impact protection and / or ventilation to the impact liner 100. In some embodiments, the helmet impact liner 100 is configured to provide topologically optimized impact attenuation over a substantial portion of, or the entirety of, the coverage area of the helmet 102. In some embodiments, the helmet impact liner 100 is comprised of foam (e.g., Expanded Poly Styrene (EPS) and / or Expanded Poly Propylene (EPP)). In some embodiments, the helmet impact liner 100 is configured to be custom fit to the contour of an individual user’s head. In some embodiments, the helmet impact liner 100 includes a plurality of vents configured to permit airflow therethrough to prevent hot spots from occurring thereby increasing the comfort of the user. In some embodiments, the impact pads 104 of the helmet impact liner 100 may be positioned within the helmet 102 such that one or more vents 103 of the helmet shell are substantially unobscured to permit airflow therethrough.

[0032] The impact pad 104 may have an exterior surface 106 configured to be removably coupled to an interior surface 110 of the helmet 102. The exterior surface 106 may be shaped andsized to conform to the curves of the helmet 102. The exterior surface 106 may flex when coupled to the interior surface 110 of the helmet 102. The exterior surface 106 may have at least one impact pad exterior fastener 1 12 disposed thereon. The impact pad exterior fastener 1 12 may be configured to engage a corresponding helmet fastener (not shown) disposed on the helmet 102. For example, the exterior fastener 112 may be one half of a hook and loop fastener that is detachably coupled to the remaining half (e.g., the helmet fastener) disposed on the interior surface 110 of the helmet 102. In some embodiments, each impact pad 104 may include one or more impact pad exterior fasteners 112. In some embodiments, an impact pad 104 includes, two impact pad exterior fasteners 112, three impact pad exterior fasteners 112, four impact pad exterior fasteners 112, five impact pad exterior fasteners 112, six impact pad exterior fasteners 112, seven impact pad exterior fasteners 112, eight impact pad exterior fasteners 112, nine impact pad exterior fasteners 112 or ten impact pad exterior fasteners 112. When more than one impact pad exterior fastener 112 is disposed on the impact pad 104, the impact pad exterior fasteners 112 may be spaced apart from one another along the exterior surface 106 of the impact pad 104.

[0033] Referring to Figs. 2B and 4, the impact pad(s) 104 may have an interior surface 108 opposite the exterior surface 106. The interior surface 108 may be substantially the same in size and / or shape as the exterior surface 106 thereof. The interior surface 108 may have at least one impact pad interior fastener 114 disposed thereon. In some embodiments, the impact pad interior fastener 114 is configured to detachably couple a cushion pad 118 to the corresponding impact pad 104. The impact pad interior fastener 114 may be configured to engage a cushion pad exterior fastener (not shown) disposed on the cushion pad 118. For example, the interior fastener 114 may be one half of a hook and loop fastener that is detachably coupled to the remaining half (e.g., the cushion pad fastener) disposed on the exterior surface of a cushion pad 118. In some embodiments, an impact pad 104 may include one or more impact pad interior fasteners 114. An impact pad 104 may include two or more impact pad interior fasteners 114. In some embodiments, an impact pad 104 includes three impact pad interior fasteners 114, four impact pad interior fasteners 114, five impact pad interior fasteners 114, six impact pad interior fasteners 114, seven impact pad interior fasteners 114, eight impact pad interior fasteners 114, nine impact pad interior fasteners 114 or ten impact pad interior fasteners 114. In some embodiments, one or more of the interior fasteners 114 may be spaced apart from one another.

[0034] In some embodiments, a substantial portion of the exterior surface of the cushion pads 118 may be a corresponding exterior fastener configured to couple to the interior fastener(s) 114 of the impact pads 104. In other embodiments, cushion pads 118 may include fasteners correspondingto the number and position of interior fasteners 114 included in the impact pad 104 to which the cushion pad 118 is configured to be coupled.

[0035] The impact pad(s) 104 may have a thickness measured between the interior surface 108 and the exterior surface 106. In some embodiments, one or more of the impact pads 104 may have a thickness of less than 30 mm. In some embodiments, one or more of the impact pads 104 may have a thickness from about 6 mm to about 20 mm. In some embodiments, one or more of the impact pads 104 have a thickness of less than 30 mm, less than 25 mm, less than 20 mm, less than 15 mm, less than 10 mm, or less than 5 mm. In some embodiments, one or more of the impact pads 104 have a thickness between 5 mm and 10 mm, between 10 mm and 15 mm, between 15 mm and 20 mm, between 20 mm and 25 mm, or between 25 mm and 30 mm. In some embodiments, each of the impact pads 104 has generally the same thickness. In other embodiments, one or more of the impact pads 104 have a thickness that is different from one or more other impact pads 104. In some embodiments, an impact pad 104 may have a generally uniform thickness.

[0036] Referring to Figs. 6 and 7A-7C, the cushion pad(s) 118 may include a cushion pad body 120 that has a generally rectangular cross-sectional shape. In some embodiments, the cushion pad body 120 for a cushion pad(s) 118 has a generally uniform thickness. The cushion pad body 120 for a cushion pad 118 may include one or more padding segments 128. For example, in Fig. 7A the cushion pad 118 includes four segments 128 and in Fig. 7B each cushion pad 118 includes a single segment 128. In some embodiments, a cushion pad body 120 for a cushion pad 118 may include two padding segments 128, three padding segments 128, four padding segments 128, five padding segments 128, six padding segments 128, seven padding segments 128, eight padding segments 128, nine padding segments 128 or more than nine padding segments 128. In some embodiments, an area between adjacent padding segments 128 (e.g., a seamline) may be generally devoid of a padding or cushioning material such that the cushion pad 118 may bend or flex about that area. The cushion pad body 120 may have a shape and size less than or equal to the impact pad 104.

[0037] In some embodiments, the cushion pads 118 may include a user engagement material. The user engagement material may include a breathable and / or moisture wicking fabric. In some embodiments, opposed surfaces of the cushion pad 118 are comprised of different materials. For example, the user engagement material is disposed on a surface (e.g., a first surface) of the cushion pad 118 configured to abut a wearer’s head and the opposite surface (e.g., a second surface) of the cushion pad 118 includes a hook and loop material configured to engage a fastener 114 on the helmet liner 100. In some embodiments, the second surface of the cushion pad 118 is comprised of a material that is denser and stronger than that of the first surface to improve comfort for a wearerwhile being securely fastened to the helmet liner 100. In some embodiments, there may be a shim positioned between an impact pad 104 and corresponding cushion pad 118. For example, a shim including corresponding hook and loop fasteners may be coupled to the interior surface of an impact pad 104 and a cushion pad 118 may be coupled to the shim such that the shim is sandwiched between the impact pad 104 and cushion pad 118. In such embodiments, the cushion pad 118 is coupled to the impact pad 104 via the corresponding shim.

[0038] Referring to Figs. 2A-4, the helmet liner 100 may include a plurality of impact pads 104 of different shapes and / or sizes. In some embodiments, a plurality of differently shaped and / or sized impact pads 104 may enable the helmet liner 100 to be used in a variety of helmet shapes and sizes. This broad utility can significantly reduce manufacturing costs and alleviate the burden of transporting additional equipment. In some embodiments, the helmet liner 100 may include five separate impact pads 104. Each impact pad 104 of the plurality of impact pads 104 may be sized and shaped to fit a different zone of the helmet 102. In some embodiments, the helmet liner 100 include a front impact pad 130, a rear impact pad 132, a crown impact pad 134 and at least one side impact pad 136.

[0039] Referring to Figs. 2A-2B and 4, the front impact pad 130, also referred to as a brow pad or front impact pad, may be shaped and sized to fit over a forehead of a user. The front impact pad 130 has a body 138 that has a generally rectangular cross-sectional shape. The body 138 may have a generally flat bottom edge 140. The bottom edge 140 may be generally flush with an edge of the helmet 102 when the front impact pad 130 is coupled thereto. The body 138 may have at least one front impact pad extension 148 extending therefrom. The front impact pad extension 148 may extend to cover areas of the user’s head proximate the forehead (e.g., the temple). In some embodiments, one or more of the impact pad exterior fasteners 112 and impact pad interior fasteners 114 may be disposed on the front impact pad extension 148.

[0040] The front impact pad 130 may have an impact pad depression 142 defined on the exterior surface thereof. The impact pad depression 142 may define a space between the front impact pad 130 and the helmet 102 when the front impact pad is coupled thereto. As described in more detail below, the impact pad depression 142 may be shaped and sized to receive the coupling tab 126 of the cushion pad 118 and / or aid a user in decoupling the front impact pad 130 from the helmet 102. In some embodiments, the front impact pad 130 may include a chamfered edge 131 configured to assist a user in decoupling the front impact pad 130 from the helmet 130. The chamfered edge may be at the front surface of the front impact pad 130 such that it faces towards the helmet 102 when the impact pad 130 is coupled thereto forming a gap between the helmet 102 and the front impact pad130. Accordingly, a user may position their fingers within the gap and grip the impact pad 130 when decoupling the impact pad 130 from the helmet 102.

[0041] Referring to Fig. 4, the front impact pad 130 may have an interior depression 150 defined on an interior surface thereof. The interior depression 150 may extend generally along the bottom edge 140. The interior depression 150 may include an interior depression fastener configured to removably couple to the outer surface of the corresponding cushion pad 118 as discussed in more detail below.

[0042] Referring to Figs. 1 and 3, the rear impact pad 132 may be shaped and sized to extend around the back of a user’s head. The rear impact pad 132 may have a body 152 with at least one neck extension 154 and at least one rear impact pad extension 156. The at least one neck extension 154 may extend toward a bottom edge of the helmet 102 when the impact pad 132 is coupled thereto. The neck extension 154 may be shaped and sized to reduce interference with the user’s neck when the user’s head rotates about the neck. There may be two neck extensions 154 extending from the body 152. A gap 158 may be defined between the two neck extensions 154. The gap 158 may form a generally acute angle. The rear impact pad extension 156 may extend from the body to areas proximate the back of the head. The impact pad exterior fastener 112 and impact pad interior fastener 114 may be disposed on either side of the rear impact pad extension 156.

[0043] The rear impact pad 132 may include an accessory aperture 160 extending through the body 152. The accessory aperture 160 may be shaped and sized to allow at least a portion of a helmet accessory (e.g., a nape pad) to extend therethrough. The rear impact pad 132 may include an accessory protrusion 162 extending therefrom. The accessory protrusion 162 may be located proximate the accessory aperture 160 and may be configured to anchor the helmet accessory to the rear impact pad. In some embodiments, the rear impact pad 132 includes a chamfered edge 133 configured to aid a user in decoupling the rear impact pad 132 from the helmet 102 in generally the same manner as discussed above for the chamfered edge 131 of the front impact pad 130.

[0044] Referring to Figs. 2A-3, the crown impact pad 134 may be configured to engage the top of a user’s head. The crown impact pad 134 may be spaced from one or more of the other impact pads 104 when coupled to the helmet 102. For example, the crown impact pad 134 may be shaped and / or sized such that it may be positioned within a space between each of the other impact pads 104 without directly contacting any one of the other impact pads 104. In some embodiments, the crown impact pad 134 is adjustably coupled to the helmet 102 such that it may be moved toward or away from one or more of the other impact pads 104 to improve the fit and / or comfort experienced by a wearer. The crown impact pad 134 may have a generally rectangular cross-sectional shape.

[0045] In some embodiments, the crown impact pad 134 is shaped and sized to couple to the interior surface 110 of helmet 102. The crown impact pad 134 may be movable relative to the helmet 102 to accommodate an inner-helmet accessory (e.g., communications headband). The crown pad 134 may be movable by about 8 mm in a fore / aft direction when the plurality of impact pads 104 are disposed in the smallest sized helmet that the plurality of impact pads 104 are configured to be disposed in (e.g., medium). The crown pad 134 may be movable about 40 mm in the fore / aft direction when the plurality of impact pads 104 are disposed in the largest sized helmet that the plurality of impact pads 104 are configured to be disposed in (e.g., extra-extra-large). The crown pad 134 may be movable between 0 mm and 50 mm when disposed in at least four different sized helmets 102. In some embodiments, the crown impact pad 134 includes one or more recessed and / or chamfered surfaces 135 configured to aid a user in removing the crown impact pad 134 from the helmet 102 in generally the same manner as the chamfered edge 131 of the front impact pad 130.

[0046] Referring to Figs. 2A-3, a side impact pad 136 may be shaped and sized to couple to the helmet 102 proximate a user’s ears. The side impact pad 136 may be configured to flex as needed to accommodate various helmet sizes. The side impact pad 136 may be movable about 8 mm in the fore / aft direction when the plurality of impact pads 104 are disposed in the smallest sized helmet that the plurality of impact pads 104 are configured to be disposed in (e.g., medium). The side impact pad 136 may be movable about 38 mm in a fore / aft direction when the plurality of impact pads 104 are disposed in the largest sized helmet that the plurality of impact pads 104 are configured to be disposed in (e.g., extra-extra-large). The side impact pad 136 may be movable between 0 mm and 40 mm when disposed in at least four different sized helmets 102.

[0047] In some embodiments, the helmet liner 100 includes two side impact pads 136, each being generally the same as one another and positioned opposite one another when coupled to the helmet 102. For example, the side impact pads 136 may be positioned at the left and right-side surfaces of the helmet 102 proximate where the wearer’s ears are. In some embodiments, the side impact pad(s) 136 include a chamfered edge 137 configured to aid a user in decoupling the side impact pads 136 from the helmet 102 in generally the same manner as described above with regards to the chamfered edge 131 of the front impact pad 130.

[0048] Referring to Figs. 2B and 7A-7C, the helmet liner 100 may include a plurality of cushion pads 118. The plurality of cushion pads 118 may be configured to be spaced from one another when coupled to the interior surface of the impact pad(s) 104. As shown in Fig. 7A, there may be a front cushion pad 182 configured to be coupled to the interior surface of the front impact pad 130. The front cushion pad 182 may include at least one segment 128. In some embodiments, the frontcushion pad 118 includes about four segments 128. The front cushion pad 182 may include the coupling tab 126 extending therefrom. The front cushion pad 182 may be shaped and sized to cover at least a portion of the front impact pad 130.

[0049] As shown in Fig. 7B, there may be one or more central cushion pads 184 configured to be coupled to the crown impact pad 134 and / or the side impact pads 136. In some embodiments, each of the central cushion pad(s) 184 includes at least one segment 128 defined therein. The central cushion pad 184 may be shaped and sized to fit on the crown impact pad 134 and at least one side impact pad 136. One central cushion pad 184 may be coupled to the side impact pad. At least one central cushion pad 184 maybe coupled to the crown impact pad 134.

[0050] As shown in Fig. 7C, there may be a rear cushion pad 186 configured to be coupled to the rear impact pad 132. The rear cushion pad 186 may include at least one segment 128 defined therein. In some embodiments, the rear cushion pad 186 includes four segments 128. The rear cushion pad 186 may be shaped and sized to cover at least a portion of the rear impact pad 132.

[0051] The plurality of cushion pads 118 may be selectively coupled to the plurality of impact pads depending on a user’s preference or to accommodate accessories within the helmet. Referring to Fig. 6, the plurality of cushion pads 118 disposed on the crown impact pad 134 may define a gap between them. This may be for user comfort, or this may be to allow a communications headband to be worn by the user. The plurality of cushion pads 118 may be shaped and sized to achieve various uses and can be coupled and decoupled to the plurality of impact pads 104 as needed.

[0052] The plurality of impact pads 104 may be configured to be spaced from one another when coupled to the interior surface 110 of the helmet 102. The plurality of impact pads 104 may be repositionable within the helmet 102 for a better user fit (e.g., for comfort or to accommodate individual head shapes). This allows the impact pad 104 to fit into multiple sized helmets 102. The plurality of impact pads 104 may be positionable relative to each other such that the impact pads 104 are adaptable for use with at least four different sized helmets 102 (e.g., medium, large, extra-large, extra- extra-large). The impact pads 104 may be considered a one-size-fits-all liner. The plurality of impact pads 104 may abut each other when coupled to a smallest helmet 102 of the different sized helmets 102. For example, if the impact pads 104 are configured to fit helmet 102 sizes medium to extra- extra-large, the plurality of impact pads 104 may abut each other when disposed in a M sized helmet. The space between abutting edges of each of the plurality of impact pads 104 increases as the size of the helmet increases without sacrificing user safety.

[0053] Each of the plurality of impact pads 104 may be under an impact area of the helmet 102 when disposed in at least four different sized helmets 102. By positioning each of the plurality ofimpact pads 104 under an impact area may result in each of the plurality of impact pads 104 having a generally standardized location in the helmet 102. For example, the crown impact pad 134 may always be on a top of the user’s head, the rear impact pad 132 may always be on the rear of the user’s head, the front impact pad 130 may always be on the front of the user’s head and the side impact pad 136 may always be on the side of the user’s head. The shape and curvature of each of the plurality of impact pads 104 may only allow the impact pad 104 to be coupled to the helmet 102 at the standardized location.

[0054] Referring to Figs. 2A-3, the plurality of impact pads 104 may define channels therebetween allowing air flow throughout the helmet 102 during use. A front-side channel 170 may be defined between the front impact pad 130 and the side impact pad 136. The front-side channel 170 may allow air to flow between an interior of the helmet and outside of the helmet 102 therethrough. The helmet 102 may include two front-side channels 170, a first front-side channel 170 on a first side and a second front-side channel 170 on a second side. A front-top channel 172 may be defined between the front impact pad 130 and the crown impact pad 134. The front -top channel 172 may allow air to flow from a first side of the helmet 102 to a second side of the helmet 102 (e.g., left to right, or right to left). A top-side channel 174 may be defined between the crown impact pad 134 and the side impact pad 136. The top-side channel 174 may allow air to flow between a front portion of the helmet 102 and a rear portion of the helmet 102 therethrough. In some embodiments, a rear-side channel 176 may be defined between the rear impact pad 132 and the side impact pad 136. The rear-side channel 176 may allow air to flow between an interior of the helmet and outside of the helmet 102 therethrough. The helmet 102 may include two rear-side channels 176, a first rear-side channel 176 on the first side and a second rear-side channel 176 the second side. A rear-top channel 178 may be defined between the rear impact pad 132 and the crown impact pad 134. The rear-top channel 178 may allow air to flow from a first side of the helmet 102 to a second side of the helmet 102 (e.g., left to right, or right to left).

[0055] An edge of each of the five impact pads 104 may be less than 50 mm from an edge of an adjacent impact pad 104 when positioned on each of the at least four different sized helmets 102. In some embodiments, an edge of each of the five impact pads 104 is less than 50 mm, less than 45 mm, less than 40 mm, less than 35 mm, less than 30 mm, less than 25 mm, less than 20 mm, less than 15 mm, less than 10 mm or less than 5 mm from an edge of an adjacent impact pad 104 when positioned on each of the at least four different sized helmets 102. In some embodiments, an edge of each of the five impact pads 104 is between 5 mm and 50 mm, between 10 mm and 45 mm, between15 mm and 40 mm, between 20 mm and 35 mm or between 25 mm and 30 mm from an edge of an adjacent impact pad 104 when positioned on each of the at least four different sized helmets 102.

[0056] The density of the impact pad 104 and the cushion pad 1 18 may be balanced to minimize the force the user experiences on the head when mobilizing and / or wearing accessories on the helmet 102 (e.g., night vision or other head borne accessories). The density of the impact pad 104 and the cushion pad 118 may conform to meet the needs of varying head-shapes and be sturdy enough not to bottom-out when using heavy helmet accessories. The impact pad 104 may comprise a composite material. The cushion pad 118 may comprise a reticulated foam or a similar material. The cushion pad 118 may comprise a breathable material (e.g., an air permeable material). The cushion pad 118 may be water and / or air permeable such that air is allowed to pass therethrough. As described in more detail below, the cushion pad 118 may allow air to pass between the impact pad 104 and the helmet 102 and through the back and sides. The impact pad 104 may have a first density. The cushion pad 118 may have a second density. The first density may be higher than the second density. In some embodiments, the first density is between about 5% to about 95% higher than the second density.

[0057] Referring to Figs. 2B and 6, during prolonged use of traditional helmets, a padding layer may shift and expose a hook-and-loop patch, causing irritation to a user’s head. One or more of the cushion pads 118 may include a coupling tab 126 extending from the cushion pad body 120. The coupling tab 126 may be coupled to the exterior surface 106 of the corresponding impact pad 104 (e.g., the front impact pad 130). The coupling tab 126 may extend from the cushion pad body 120 at a central portion thereof. The coupling tab 126 may be a length of the user engagement material. In some embodiments, the coupling tab 126 comprises a webbing. The coupling tab 126 may couple to the exterior surface 106 of the impact pad 104. In some embodiments, the coupling tab 126 includes one or more fasteners configured to engage with a corresponding fastener of the front impact pad 130. In some embodiments, the coupling tab 126 may wrap around a bottom edge 140 of the front impact pad 130 and be received within the impact pad depression 142.

[0058] The impact pad depression 142 defined on the impact pad 104 may include a first fastener. In some embodiments, the coupling tab 126 includes one half of a hook and loop fastener configured to engage with the first fastener positioned within the impact pad depression 142. The first fastener may cover at least a portion of the impact pad depression 142. In some embodiments, the first fastener covers the entire impact pad depression 142.

[0059] The coupling tab 126 may extend around the bottom edge 140 of the impact pad 104 and couple to the first fastener of the impact pad depression 142. Engagement of the coupling tab 126and the impact pad depression 142 may couple the cushion pad 118 to the impact pad 104. As mentioned above, preventing the cushion pad 118 from moving relative to the impact pad 104 during use may prevent the cushion pad 118 from moving up the forehead of the user and may reduce irritation and overall discomfort for the user.

[0060] Referring to Figs. 2B and 7A, the coupling tab 126 of the front cushion pad 182 may include a coupling area 164 configured to engage with the first fastener at the impact pad depression 142. The coupling area 164 may have a common shape and size with the impact pad depression 142. In some embodiments, the coupling area 164 is smaller than the impact pad depression 142. In some embodiments, the front cushion pad 182 includes two coupling tabs 126 each including a coupling area 164. The coupling area 164 may include a second fastener. The second fastener may be configured to removably couple to the first fastener. The first fastener and the second fastener may be hook-and-loop fabric or another acceptable coupling material.

[0061] Referring to Figs. 1 and 8, in some embodiments, the helmet liner 100 includes a nape mount 190 configured to couple a nape pad (e.g., rear cushion pad 186) to the helmet liner 100. The nape mount 190 may include a nape plate 191 configured to receive the nape pad and a cable anchor 192 configured to adjust the position of the nape plate 191. The nape mount 190 may be coupled to the rear impact pad 132 via the nape plate 191. In some embodiments, the nape plate 191 includes an arm 193 engaged with the accessory protrusion 162 and adjustably coupling the nape plate 191 to the rear impact pad 132. In some embodiments the nape plate 191 includes one or more fasteners194 configured to engage corresponding fasteners of a nape pad. For example, the fasteners 194 may be hook patches configured to engage corresponding loops disposed on a surface of the nape pad (e.g., a hook and loop fastener).

[0062] The cable anchor 192 may be configured to be fixedly coupled to a helmet shell (e.g., helmet 102). In some embodiments, the cable anchor 192 includes one or more apertures 195 configured to receive a fastener coupled to the helmet 102. For example, a bolt or screw extending through the helmet 102 may extend through the apertures 195 to couple the cable anchor 192 thereto. In some embodiments, the cable anchor 192 includes a pair of apertures 195 at opposite sides of the cable anchor 192. In some embodiments each aperture 195 includes a series of indexed apertures corresponding to helmets 102 of a different size. For example, in Figs. 7-8 the apertures195 include four indexed apertures corresponding to four different sized helmets 102. It should be understood though that there may be any number of indexed apertures for receiving a fastener to couple the cable anchor 192 to the helmet 102.

[0063] In some embodiments, the cable anchor 192 is fixed in position relative to the helmet shell 102 and the nape plate 191 is movable relative to the helmet 102. For example, the cable anchor 192 remains fixed in position while the nape plate 191 flexes or rotates about the protrusion 162 via arm 193. In some embodiments, the nape mount 190 includes an adjustment knob 196 coupled to the nape plate 191 and configured to adjust the position of the nape plate 191 relative to the helmet 102. The adjustment knob 196 may be coupled to one or more cables 197 that are coupled to the cable anchor 192. The cables 197 may include opposed terminal ends fixed relative to the cable anchor 192 and the knob 196. Accordingly, when the adjustment knob 196 is rotated in a first direction the cables 197 are wound around the adjustment knob 196 thereby pulling the nape plate 191 towards the front impact pad 130. Rotation of the adjustment knob 196 in the opposite direction may cause the cables 197 to unwind from the adjustment knob 196 allowing the nape plate 191 to move away from the front impact pad 130.

[0064] In some embodiments, the adjustment knob 196 includes a locking mechanism configured to prevent the nape plate 191 from accidentally or unintentionally moving relative to the helmet 102. For example, following rotation of the adjustment knob 196 the locking mechanism may cause the knob 196 to be retained in the rotated position thereby preventing the wires 197 from unwinding and causing the nape plate 191 to move unintentionally. In some embodiments, the nape plate 191 and / or cable anchor 192 includes one or more cable management features through which the cables 197 extend.

[0065] Referring to Figs. 9-10, there is shown a helmet liner, generally designated 200, in accordance with another exemplary embodiment of the present disclosure. The helmet liner 200 may be generally the same as helmet liner 100 except that it may include at least one venting aperture 244 and an exterior recess 246 at the front impact pad 230. In Fig. 9 the portions of the helmet impact line 200 obscured by the helmet shell 202 are depicted in broken lines. In Fig. 9 one or more fasteners and / or mounting features (e.g., accessory rail mounts, shroud mounts) have been omitted for illustration purposes. Incorporating a vent in the helmet liner 200 facilitates efficient heat dissipation, preventing overheating and enhancing overall comfort for users during prolonged use. Additionally, ventilation supports moisture management, reducing the risk of fogging on visors and ensuring clear visibility. A well-designed vent contributes to weight reduction without compromising protective capabilities, alleviating the physical burden on a user. The venting aperture 244 and / or exterior recess 246 may allow air to flow into the spaces between the impact pads 204, thereby reducing the internal temperature in the helmet shell 202. The impact pads 204 may be generally the same as impact pads 104 discussed above.

[0066] The at least one venting aperture 244 and exterior recess 246 on the front impact pad 230 may define a space between the helmet shell 202 and the front impact pad 230. The space between the helmet 202 and the front impact pad 230 may be in fluid communication with a cushion pad coupled to the front impact pad 230 and / or one of the other impact pads 204 through the venting aperture 244. The air may be able to move freely between the forehead, the spaces between the impact pads 204 and the edge of the helmet shell 202. In some embodiments, one or more other impact pads 204 include ventilation (e.g., venting aperture(s) fluidly coupled to exterior recesses) similar to that of front impact pad 230.

[0067] The at least one venting aperture 244 may include two venting apertures 244 spaced apart from each other. The two venting apertures 244 may be spaced apart from the impact pad depression 242 defined on the exterior surface of the front impact pad 230.

[0068] The term “about” or “approximately” is used herein to provide literal support for the exact number that it precedes, as well as a number that is near to or approximately the number that the term precedes. In determining whether a number is near to or approximately a specifically recited number, the near or approximating unrecited number may be a number, which, in the context in which it is presented, provides the substantial equivalent of the specifically recited number. It should be appreciated that all numerical values and ranges disclosed herein are approximate values and ranges, whether “about” is used in conjunction therewith. It should also be appreciated that the term “about,” as used herein, in conjunction with a numeral refers to a value that may be ±0.01% (inclusive), ±0.1% (inclusive), ±0.5% (inclusive), ±1% (inclusive) of that numeral, ±2% (inclusive) of that numeral, ±3% (inclusive) of that numeral, ±5% (inclusive) of that numeral, ±10% (inclusive) of that numeral, or ±15% (inclusive) of that numeral. It should further be appreciated that when a numerical range is disclosed herein, any numerical value falling within the range is also specifically disclosed.

[0069] It will be appreciated by those skilled in the art that changes could be made to the exemplary embodiments shown and described above without departing from the broad inventive concepts thereof. It is to be understood that the embodiments and claims disclosed herein are not limited in their application to the details of construction and arrangement of the components set forth in the description and illustrated in the drawings. Rather, the description and the drawings provide examples of the embodiments envisioned. The embodiments and claims disclosed herein are further capable of other embodiments and of being practiced and carried out in various ways. Specific features of the exemplary embodiments may or may not be part of the claimed invention and various features of the disclosed embodiments may be combined. Unless specifically set forthherein, the terms “a”, “an” and “the” are not limited to one element but instead should be read as meaning “at least one”. Finally, unless specifically set forth herein, a disclosed or claimed method should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the steps may be performed in any practical order.

Claims

CLAIMSWhat is claimed is:

1. A helmet impact liner comprising: an impact pad having an exterior surface configured to be removably coupled to an interior surface of a helmet, and an interior surface opposite the exterior surface; and a cushion pad having a cushion pad body, an exterior surface removably coupled to the interior surface of the impact pad, an interior surface opposite the exterior surface, and a coupling tab extending from the cushion pad body and coupled to the exterior surface of the impact pad.

2. The helmet impact liner of claim 1, wherein the impact pad further comprises: an impact pad depression defined on the exterior surface thereof, the impact pad depression located at a central portion of the impact pad and abutting a bottom end of the impact pad, and wherein the impact pad depression includes a first fastener.

3. The helmet impact liner of claim 2, wherein the coupling tab extends around the bottom end of the impact pad and couples to the first fastener of the impact pad depression.

4. The helmet impact liner of claim 3, wherein engagement of the coupling tab and the impact pad depression couples the cushion pad to the impact pad.

5. The helmet impact liner of claim 2, wherein the coupling tab comprises a coupling area defined on an end opposite the cushion pad body, the coupling area comprising a second fastener configured to removably couple to the first fastener.

6. The helmet impact liner of claim 5, wherein the coupling area and the impact pad depression are a common size and shape.

7. The helmet impact liner of claim 5, wherein the first fastener and the second fastener are hook-and-loop fasteners.

8. The helmet impact liner of claim 1, wherein the impact pad comprises a plurality of impact pads configured to be spaced from one another when coupled to the interior surface of the helmet.

9. The helmet impact liner of claim 8, wherein the impact pad comprises five impact pads.

10. The helmet impact liner of claim 1, wherein the cushion pad comprises a plurality of cushion pads configured to be spaced from one another when coupled to the interior surface of the impact pad.

11. The helmet impact liner of claim 1, wherein the impact pad has a first density and the cushion pad has a second density, and wherein the first density is higher than the second density.

12. A helmet comprising: a helmet shell having an inner surface; an impact pad having an exterior surface removably coupled to the inner surface of the helmet, and an interior surface opposite the exterior surface; and a cushion pad having a cushion pad body, an exterior surface removably coupled to the interior surface of the impact pad, an interior surface opposite the exterior surface, and a coupling tab extending from the cushion pad body and coupled to the exterior surface of the impact pad.

13. The helmet of claim 12, wherein the impact pad comprises five impact pads positioned on the inner surface of the helmet.

14. The helmet of claim 13, wherein the impact pads are positionable relative to each other.

15. The helmet of claim 14, wherein an edge of each of the five impact pads is between about 8 mm to about 40 mm from an edge of an adjacent impact pad when positioned on the inner surface of the helmet.

16. The helmet of claim 12, the impact pad further comprising: an impact pad depression defined on the exterior surface thereof, the impact pad depression located at a central portion of the impact pad and abutting a bottom end of the impact pad, wherein the impact pad depression includes a first fastener.

17. The helmet of claim 16, wherein the coupling tab extends around the bottom end of the impact pad and couples to the first fastener of the impact pad depression.

18. A helmet compri sing : a helmet shell having an inner surface; a plurality of impact pads, each having an exterior surface removably coupled to the inner surface of the helmet, an interior surface opposite the exterior surface, and an impact pad depression defined on the exterior surface of at least one of the plurality of impact pads, the impact pad depression abutting a bottom end of the impact pad and including a first fastener; and a plurality of cushion pads, each having a cushion pad body, an exterior surface removably coupled to the interior surface of the impact pad, an interior surface opposite the exterior surface, and a coupling tab extending from the cushion pad body and coupled to the exterior surface of the impact pad, wherein at least one of the plurality of impact pads having a chamfered edge at the exterior surface thereof facing towards the inner surface of the helmet shell , and wherein the coupling tab extends around the bottom end of the impact pad and couples to the first fastener of the impact pad depression.

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