Comfort padding

Abstract

A comfort padding layer for use within protective apparel, comprising: a layer of compressible material configured to provide cushioning for comfort and / or fitting of the protective apparel to a wearer; a backing layer attached to the layer of compressible material, wherein the backing layer is configured, when used within the protective apparel, to face an inner surface of an outer part of the protective apparel and slide relative to the inner surface in response to an oblique impact to the outer part of the protective apparel, such that the comfort padding layer can move relative to the outer part of the protective apparel; one or more attachment points, provided on the backing layer, at which the backing layer is configured to be detachably attached to the outer part of the protective apparel; a stiffening layer, provided at least at one or more portions of the backing layer corresponding to the one or more attachment points, configured to provide increased stiffness to the comfort padding layer in order to facilitate relative sliding between the backing layer and the inner surface of the outer part of the protective apparel in response to an oblique impact to the protective apparel.

Description

[0001] COMFORT PADDING

[0002] TECHNICAL FIELD

[0003] The present disclosure relates to comfort padding for protective apparel, such as a helmet.

[0004] BACKGROUND ART

[0005] Impact protection apparatuses generally aim to reduce the energy transferred to an object, such as a person to be protected, by an impact. This may be achieved by energy absorbing means, energy redirecting means, or a combination thereof. Energy absorbing means may include energy absorbing materials, such as a foam material, or structures configured to deform elastically and / or plastically in response to an impact. Energy redirecting means may include structures configured to slide, shear or otherwise move in response to an impact.

[0006] Impact protection apparatuses include protective apparel for protecting a wearer of the apparel. Protective apparel comprising energy absorbing means and / or energy redirecting means is known. For example, such means are implemented extensively in protective headgear, such as helmets.

[0007] Examples of helmets comprising energy absorbing means and energy redirecting means include WO 2001 / 045526 and WO 2011 / 139224 (the entirety of which are herein incorporated by reference). Specifically, these helmets include at least one layer formed from an energy absorbing material and at least one layer that can move relative to the head of the wearer of the helmet under an impact.

[0008] Implementing moving parts in protective apparel has challenges. For example, ensuring that friction between moving parts under an impact can be overcome to allow enough relative movement between parts can be challenging. Ensuring that the protective apparel can be manufactured and assembled relatively easily can be challenging

[0009] It is the aim of the present invention to provide protective apparel that at least partially addresses some of the problems discussed above. STATEMENTS OF THE INVENTION

[0010] According to an aspect of the disclosure, there is provided a comfort padding layer for use within protective apparel, comprising: a layer of compressible material configured to provide cushioning for comfort and / or fitting of the protective apparel to a wearer; a backing layer attached to the layer of compressible material, wherein the backing layer is configured, when used within the protective apparel, to face an inner surface of an outer part of the protective apparel and slide relative to the inner surface in response to an oblique impact to the outer part of the protective apparel, such that the comfort padding layer can move relative to the outer part of the protective apparel; one or more attachment points, provided on the backing layer, at which the backing layer is configured to be detachably attached to the outer part of the protective apparel; a stiffening layer, provided at least at one or more portions of the backing layer corresponding to the one or more attachment points, configured to provide increased stiffness to the comfort padding layer in order to facilitate relative sliding between the backing layer and the inner surface of the outer part of the protective apparel in response to an oblique impact to the protective apparel.

[0011] Optionally, the stiffening layer is configured to facilitate detachment of the attachment points from the outer part of the protective apparel in response to an oblique impact to the helmet, to enable relative sliding between the backing layer and the inner surface of the outer part of the protective apparel in response to an oblique impact to the protective apparel.

[0012] Optionally, the stiffening layer is formed such that the comfort padding layer is flexible and able to substantially conform to the shape of the inner surface of the outer part of the protective apparel and / or the wearer.

[0013] Optionally, the stiffening layer is configured to provide increased tensile stiffness to the backing layer in order to reduce stretching of the backing layer resulting from a tangential force at the one or more attachment points.

[0014] Optionally, the stiffening layer is configured so as to not substantially increase the bending stiffness of the backing layer.

[0015] Optionally, the backing layer is formed from a soft material.

[0016] Optionally, the stiffening layer is immovably fixed to the backing layer.

[0017] Optionally, the stiffening layer is provided on an inner side of the backing layer, on an opposite side to the outer part of the protective apparel when the comfort padding inner layer us used within the protective apparel.

[0018] Optionally, the stiffening layer extends over substantially all of the backing layer.

[0019] Optionally, the stiffening layer is formed from a synthetic polymer material.

[0020] Optionally, the stiffening layer is formed from a non-woven fabric material.

[0021] Optionally, the stiffening layer is formed from a spunbond polyethylene fibre material.

[0022] Optionally, the stiffening layer is formed from a breathable material.

[0023] Optionally, the stiffening layer comprises treated and untreated portions, wherein the stiffness of the treated portions is greater than the stiffness of the untreated portions.

[0024] Optionally, the breathability of the untreated portions is higher than the breathability of the treated portions.

[0025] Optionally, the treated portions are provided to surround the untreated portions, and are provided at portions corresponding to the compressible material configured to provide cushioning.

[0026] Optionally, the attachment points are arranged at locations corresponding to the untreated portions.

[0027] Optionally, the treated portions are treated with heat and / or pressure and / or chemical treatment and / or application of a coating.

[0028] Optionally, the treated portions of the stiffening layer bond the stiffening layer to the backing layer and / or the layer of compressible material.

[0029] Optionally, the treated portions are treated using a high frequency welding process.

[0030] According to a second aspect of the disclosure, there is provided protective apparel comprising an outer part and a comfort padding layer according to the preceding aspect, arranged on an inner side of the outer part closer to a wearer.

[0031] Optionally, the outer part comprises an energy absorbing layer and / or an outer shell.

[0032] Optionally, in either of the above aspects, the protective apparel is a helmet.

[0033] According to a third aspect of the disclosure there is provided a method of forming the comfort padding of any preceding aspect comprising: arranging the layer of compressible material and stiffening layer on top of each other; and welding the layer of compressible material and stiffening layer at one or more attachment portions.

[0034] Optionally, the backing layer is additionally arranged adjacent the stiffening layer, on an opposite side to the layer of compressible material, and welded.

[0035] Optionally, a covering layer is additionally arranged adjacent the layer of compressible material, on an opposite side to the stiffening layer, and welded.

[0036] Optionally, the welding step is performed by a high frequency welding process.

[0037] BRIEF DESCRIPTION OF THE DRAWINGS

[0038] The invention is described in detail below, with reference to the accompanying figures, in which:

[0039] Fig. 1 schematically shows a cross-section through a first example helmet;

[0040] Fig. 2 schematically shows a cross-section through a second example helmet; Fig. 3 schematically shows a cross-section through a third example helmet;

[0041] Fig. 4 schematically shows a cross-section through a fourth example helmet;

[0042] Fig. 5 schematically shows a cross-section through a fifth example helmet;

[0043] Fig. 6 schematically shows a cross-section through a sixth example helmet;

[0044] Fig. 7 schematically shows a cross-section through a seventh example helmet;

[0045] Fig. 8 shows an eighth example helmet;

[0046] Fig. 9 shows a first example of body armour;

[0047] Fig. 10 shows a second example of body armour;

[0048] Fig. 11 schematically shows a cross-section through a ninth example helmet;

[0049] Fig. 12 schematically depicts, in a cross-section, another arrangement of a helmet;

[0050] Fig. 13 depicts the inside of an example of a helmet according to the arrangement depicted in Fig.12;

[0051] Fig. 14 schematically shows layer forming a comfort padding layer;

[0052] Fig. 15 schematically shows layer forming a comfort padding layer.

[0053] DETAILED DESCRIPTION

[0054] Unless otherwise state, it should be noted that the Figures are schematic, the proportions of the thicknesses of the various layers, and / or of any gaps between layers, depicted in the Figures have been exaggerated for the sake of clarity and can of course be adapted according to need and requirements.

[0055] Although the examples described below relate to helmets, it should be understood that the invention applies generally to protective apparatuses, including other types of headgear and other protective apparel.

[0056] Protective apparatuses can be understood to have parts corresponding to the parts of the helmets described below. For example, protective apparatuses may have a layered structure corresponding to the layered structure of the described helmets.

[0057] Terms that are specific to a helmet, such as “radial direction” can be understood to have equivalents in the context of other protective equipment, such as “thickness direction”. A “wearer” is to generally understood as corresponding to an object that is to be protected by the protective apparatus, and “head” as a specific part of the object, e g a different body part, with which the apparatus is in contact.

[0058] General features of the example helmets are described below with reference to Figs. 1 to 7.

[0059] Figs. 1 to 7 show example helmets 1 comprising an energy absorbing layer 3. The purpose of the energy absorbing layer 3 is to absorb and dissipate energy from an impact in order to reduce the energy transmitted to the wearer of the helmet. Within the helmet 1, the energy absorbing layer may be the primary energy absorbing element. Although other elements of the helmet 1 may absorb that energy to a more limited extent, this is not their primary purpose.

[0060] The energy absorbing layer 3 may absorb energy from a radial component of an impact more efficiently than a tangential component of an impact. The term “radial” generally refers to a direction substantially toward the centre of the wearers head, e.g. substantially perpendicular to an outer surface of the helmet 1. The term “tangential” may refer to a direction substantially perpendicular to the radial direction, in a plane comprising the radial direction and the impact direction.

[0061] The energy absorbing layer may be formed from an energy absorbing material, such as a foam material. Preferable such materials include expanded polystyrene (EPS), expanded polypropylene (EPP), expanded polyurethane (EPU), vinyl nitrile foam; or strain rate sensitive foams such as those marketed under the brand-names Poron™ and D3O™.

[0062] Alternatively, or additionally, the energy absorbing layer may have a structure that provides energy absorbing characteristics. For example, the energy absorbing layer may comprise deformable elements, such as cells or finger-like projections, that deform upon impact to absorb and dissipate the energy of an impact.

[0063] As illustrated in Fig. 6, the energy absorbing layer 3 of the helmet 1 is divided into outer and inner parts 3A and 3B.

[0064] As illustrated in Fig 11, the energy absorbing layer 3 may be divided into multiple parts arranged adjacent each other in the circumferential direction of the helmet. Figure 11 shows such a helmet 1 of the type shown in Fig. 6, with the inner parts 3B being formed in front and back parts 3C and 3D.

[0065] The energy absorbing layer is not limited to one specific arrangement or material. The energy absorbing layer 3 may be provided by multiple layers having different arrangements, i.e. formed from different materials or having different structures. The energy absorbing layer 3 may be a relatively thick layer. For example, it may be thickest layer of the helmet 1.

[0066] Figs. 1 to 7 show example helmets 1 comprising an outer layer 2. The purpose of the outer layer 2 may be to provide rigidity to the helmet. This may help spread the impact energy over a larger area of the helmet 1. The outer layer 2 may also provide protection against objects that might pierce the helmet 1. Accordingly, the outer layer may be a relatively strong and / or rigid layer, e.g. compared to an energy absorbing layer 3. The outer layer 2 may be a relatively thin layer, e.g. compared to an energy absorbing layer 3. The outer layer 2 may be an outer shell.

[0067] The outer layer 2 may be formed from a relatively strong and / or rigid material. Preferable such materials include a polymer material such as polycarbonate (PC), polyvinylchloride (PVC) or acrylonitrile butadiene styrene (ABS) for example. Advantageously, the polymer material may be fibre-reinforced, using materials such as glass-fibre, Aramid, Twaron, carbon-fibre and / or Kevlar.

[0068] As shown in Fig. 7, one or more outer plates 7 may be mounted to the outer layer 2 of the helmet 1. The outer plates 7 may be formed from a relatively strong and / or rigid material, for example from the same types of materials as from which the outer layer 2 may be formed. The selection of material used to form the outer plates 7 may be the same as, or different from, the material used to form the outer layer 2.

[0069] In some example helmets, the outer layer 2 and / or the energy absorbing layer 3 may be adjustable in size in order to provide a customised fit. For example, the outer layer 2 may be provided in separate front and back parts. The relative position of the front and back parts may be adjusted to change the size of the outer layer 2. In order to avoid gaps in the outer layer 2, the front and back parts may overlap. The energy absorbing layer 3 may also be provided in separate front and back parts. These may be arranged such that the relative position of the front and back parts may be adjusted to change the size of the energy absorbing layer 3. In order to avoid gaps in the energy absorbing layer 3, the front and back parts may overlap.

[0070] Figs. 1 to 4 shows example helmets 1 comprising an interface layer 4. Although not shown in Figs. 5 to 7, these example helmets may also comprise an interface layer 4. The purpose of interface layer 4 may be to provide an interface between the helmet and the wearer. In some arrangements, this may improve the comfort of the wearer. The interface layer 4 may be provided to mount the helmet on the head of a wearer. The interface layer 4 may be provided as a single part or in multiple sections.

[0071] The interface layer 4 may be configured to at least partially conform to the head of the wearer. For example, the interface layer 4 may be elasticated and / or may comprise an adjustment mechanism for adjusting the size of the interface layer 4. In an arrangement, the interface layer may engage with the top of a wearer’s head. Alternatively, or additionally, the interface layer 4 may comprise an adjustable band configured to encircle the wearer’s head.

[0072] The interface layer 4 may comprise comfort padding 4A. Multiple sections of comfort padding 4A may be provided. The comfort padding 4A may be provided on a substrate 4B for mounting the comfort padding to the rest of the helmet 1.

[0073] The purpose of the comfort padding 4A is to improve comfort of wearing the helmet and / or to provide a better fit. The comfort padding may be formed from a relatively soft material, e.g. compared to the energy absorbing layer 3 and / or the outer layer 2. The comfort padding 4A may be formed from a foam material. However, the foam material may be of lower density and / or thinner than foam materials used for the energy absorbing layer 3. Accordingly, the comfort padding 4A will not absorb a meaningful amount of energy during an impact, i.e. for the purposes of reducing the harm to the wearer of the helmet. Comfort padding is well recognised in the art as being distinct from energy absorbing layers, even if they may be constructed from somewhat similar materials.

[0074] The interface layer 4, and / or comfort padding 4A that may be part of it, may be removable. This may enable the interface layer 4 and / or comfort padding 4 A to be cleaned and / or may enable the provision of an interface layer 4 and / or comfort padding 4A that is configured to fit a specific wearer.

[0075] Straps, e.g. chin straps, may be provided to secure the helmet 1 to the head of the wearer.

[0076] The helmets of Figs. 1 to 4 are configured such that the interface layer 4 is able to move, for example slide, in a tangential direction relative to the energy absorbing layer 3 in response to an impact. As shown in Figs. 1 to 4, the helmet 1 may also comprise connectors 5 between the energy absorbing layer 3 and the interface layer 4 that allow relative movement between the energy absorbing layer 3 and the interface layer 4, while connecting the elements of the helmet together.

[0077] The helmet of Fig. 5 is configured such that the outer layer 2 is able to move, for example slide, in a tangential direction relative to the energy absorbing layer 3 in response to an impact. As shown in Fig 5, the helmet 1 may also comprise connectors 5 between the energy absorbing layer 3 and the outer layer 2 that allow relative movement between the energy absorbing layer 3 and the outer layer 2, while connecting the elements of the helmet together.

[0078] The helmet of Fig. 6 is configured such that the outer part 3A of the energy absorbing layer 3 is able to move, for example slide, in a tangential direction relative to the inner part 3B of the energy absorbing layer 3 in response to an impact. As shown in Fig 6, the helmet 1 may also comprise connectors 5 between the outer part 3A of the energy absorbing layer 3 and the inner part 3B of the energy absorbing layer 3, that allow relative movement between the outer part 3A of the energy absorbing layer 3 and the inner part 3B of the energy absorbing layer 3, while connecting the elements of the helmet together.

[0079] In examples, such as that of Fig. 11, in which an energy absorbing layer is split into multiple parts 3C and 3D arranged adjacent each other in the circumferential direction of the helmet, these parts may be configured to move relative to each other, as well as other parts of the helmet.

[0080] The helmet 1 of Fig. 7 is configured such that the outer plates 7 are able to move, for example slide, in a tangential direction relative to the outer layer 2 in response to an impact. As shown in Fig 7, the helmet 1 may also comprise connectors 5 between the outer plates 7 and the outer layer 2 that allow relative movement between the outer plates 7 and the outer layer 2, while connecting the elements of the helmet together.

[0081] The purpose of helmet layers that move or slide relative to each other may be to redirect energy of an impact that would otherwise be transferred to the head the wearer. This may improve the protection afforded to the wearer against a tangential component of the impact energy. A tangential component of the impact energy would normally result in rotational acceleration of the head of the wearer. It is well know that such rotation can cause brain injury. It has been shown that helmets with layers that move relative to each other can reduce the rotational acceleration of the head of the wearer. A typical reduction may be roughly 25% but reductions as high as 90% may be possible in some instances.

[0082] Preferably, relative movement between helmet layers results in a total shift amount of at least 0.5cm between an outermost helmet layer and an inner most helmet layer, more preferably at least 1cm, more preferably still at least 1.5cm. Preferably the relative movement can occur in any direction, e.g. in a circumferential direction around the helmet, left to right, front to back and any direction in between.

[0083] Relative movement can be considered to occur substantially in a plane over the relevant ranges, even though movement between layers may be rotational rather than linear. Accordingly, reference may be made below to movement in a plane.

[0084] Regardless of how helmet layers are configured to move relative to each other, it is preferable that the relative movement, such as sliding, is able to occur under forces typical of an impact for which the helmet is designed (for example an impact that is expected to be survivable for the wearer). Such forces are significantly higher than forces that a helmet may be subject to during normal use. Impact forces tend to compress layers of the helmet together, increasing the reaction force between components and thus increasing frictional forces. Where helmets are configured to have layers sliding relative to each other the interface between them may need to be configured to enable sliding even under the effect of the high reaction forces experienced between them under an impact.

[0085] As shown in Figs. 1 to 7, a sliding interface may be provided between the layers of the helmet 1 that are configured to slide relative to each other. At the sliding interface, surfaces slide against each other to enable relative sliding between the layers of the helmet 1. The sliding interface may be a low friction interface. Accordingly, friction reducing means may be provided at the sliding interface. Example sliding interfaces are described further below, in relation to each of the example helmets 1 shown in Figs. 1 to 7.

[0086] The friction reducing means may be a low friction material or lubricating material. These may be provided as a continuous layer, or multiple discrete patches, or portions of material, for example. Possible low friction materials for the friction reducing means include waxy polymers such as PC, PTFE, ABS, PVC, Nylon, PF A, FEP, PE and UHMWPE, Teflon™, a woven fabric such as Tamarack™, a non-woven fabric, such a felt. Such low friction materials may have a thickness of roughly 0.1-5 mm, but other thicknesses can also be used, depending on the material selected and the performance desired. Possible lubricating materials include oils, polymers, microspheres, or powders. Combinations of the above may be used.

[0087] In one example, the low friction material or lubricating material may be a polysiloxane- containing material. In particular the material may comprise (i) an organic polymer, a polysiloxane and a surfactant; (ii) an organic polymer and a copolymer based on a polysiloxane and an organic polymer; or (iii) a non-elastomeric cross-linked polymer obtained or obtainable by subjecting a polysiloxane and an organic polymer to a crosslinking reaction. Preferred options for such materials are described in WO 2017 / 148958 (the entirety of which is herein incorporated by reference).

[0088] In one example, the low friction material or lubricating material may comprise a mixture of (i) an olefin polymer, (ii) a lubricant, and optionally one or more further agents. Preferred options for such materials are described in WO 2020 / 115063 (the entirety of which is herein incorporated by reference).

[0089] In one example, the low friction material or lubricating material may comprise an ultra high molecular weight (UHMW) polymer having a density of < 960 kg / m3, which UHMW polymer is preferably an olefin polymer. Preferred options for such materials are described in WO 2020 / 115063. In one example, the low friction material or lubricating material may comprise a polyketone. Preferred options for such materials are described in WO 2020 / 260185 (the entirety of which is herein incorporated by reference).

[0090] In some arrangements, it may be desirable to configure the low friction interface such that the static and / or dynamic coefficient of friction between materials forming sliding surfaces at the sliding interface is between 0.001 and 0.3 and / or below 0.15. The coefficient of friction can be tested by standard means, such as standard test method ASTM D1894.

[0091] The friction reducing means may be provided on, or be an integral part of, one or both of the layers of the helmet 1 that are configured to slide relative to each other. In some examples, helmet layers may be configured to have a dual function, including functioning as a friction reducing means. Alternatively, or additionally, the friction reducing means may be separate from the layers of the helmet 1 that are configured to slide relative to each other, but provided between the layers.

[0092] Instead of the sliding interface, in some examples, a shearing interface may be provided between the layers of the helmet 1 that are configured to move relative to each other. At the shearing interface, a shearing layer shears to enable relative movement between the layers of the helmet 1. The shearing layer may comprise a gel or liquid, which may be retained within a flexible envelope. Alternatively, the shearing layer may comprise two opposing layers connected by deformable elements that deform to enable shearing between the two opposing layers.

[0093] A single shearing layer may be provided that substantially fills the volume between two layers of a helmet. Alternatively, one or more shearing layers may be provided that fill only a portion of the volume between two layers of a helmet, e.g. leaving substantial space around the shearing layers. The space may comprise a sliding interface, as described above. As such, helmets may have a combination of shearing and sliding interfaces. Such shearing layers may act as connectors 5, which are described further below.

[0094] Figs. 1 to 7 schematically show connectors 5 . The connectors 5 are configured to connect two layers of the helmet while enabling relative movement, e.g. sliding or shearing, between the layers. Different numbers of connectors 5 may be provided than as shown in Figs. 1 to 7. The connectors 5 may be located at different positions than as shown in Figs. 1 to 7, for example at a peripheral edge of the helmet 1 instead of a central portion.

[0095] Typically, a connector 5 comprises first and second attachment parts respectively configured to attach to first and second parts of the helmet and a deformable part between the first and second attachment parts that enables the first and second attachment parts to move relative to each other to enable movement between the first and second parts of the helmet. Connectors 5 may absorb some impact energy by deforming.

[0096] The specific arrangements of each of the example helmets shown in Figs. 1 to 7 are described below.

[0097] Fig. 1 shows a helmet 1 comprising an outer layer 2, an energy absorbing layer 3 and an interface layer 4. The interface layer 4 is provided as a single layer and comprises comfort padding.

[0098] The helmet 1 of Fig. 1 is configured such that the interface layer 4 is able to slide relative to the energy absorbing layer 3 in response to an impact. A sliding interface is provided between the interface layer 4 and the energy absorbing layer 3.

[0099] A sliding layer 6 is provided on a surface of the energy absorbing layer 3 facing the sliding interface. The sliding layer 6 may be moulded to the energy absorbing layer 3 or otherwise attached thereto. The sliding layer 6 may be formed from a relatively hard material, e.g. relative to the energy absorbing layer 3. The sliding layer 6 is configured to provide friction reducing means to reduce the friction at the sliding interface. This may be achieved by forming the sliding layer 6 from a low friction material, such as PC, PTFE, ABS, PVC, Nylon, PF A, FEP, PE and UHMWPE. Alternatively, or additionally, this may be achieved by applying a low friction coating to the sliding layer 6, and / or applying a lubricant to the sliding layer 6.

[0100] Alternatively or additionally, friction reducing means, to reduce the friction at the sliding interface, may be provided by forming the energy absorbing layer 3 from a low friction material, by applying a low friction coating to the energy absorbing layer 3, and / or applying a lubricant to the energy absorbing layer 3. The helmet 1 shown in Fig. 1 also comprises connectors 5 attached to the interface layer 4. The connectors are also connected to the sliding layer 6 to allow relative sliding between the energy absorbing layer 3 and the interface layer 4. Alternatively, or additionally, one or more of the connectors 5 may be connected to another part of the remainder of the helmet 1, such as the energy absorbing layer 3 or the outer layer 2. The connectors 5 may also be connected to two or more parts of the remainder of the helmet 1.

[0101] It should be understood that such an arrangement of the energy absorbing layer 3 and the interface layer 4 may be added to any helmet described herein.

[0102] Fig. 2 shows a helmet 1 comprising an outer layer 2, an energy absorbing layer 3 and an interface layer 4. The interface layer 4 is provided as a plurality of independent sections each comprising comfort padding.

[0103] The helmet 1 of Fig. 2 is configured such that the sections of the interface layer 4 are able to slide relative to the energy absorbing layer 3 in response to an impact. A sliding interface is provided between the sections of the interface layer 4 and the energy absorbing layer 3.

[0104] A sliding layer 6 is provided on a surface of the energy absorbing layer 3 facing the sliding interface. The sliding layer 6 may be moulded to the energy absorbing layer 3 or otherwise attached thereto. The sliding layer 6 may be formed from a relatively hard material, e.g. relative to the energy absorbing layer 3. The sliding layer 6 is configured to provide friction reducing means to reduce the friction at the sliding interface. This may be achieved by forming the sliding layer 6 from a low friction material, such as PC, PTFE, ABS, PVC, Nylon, PF A, FEP, PE and UHMWPE. Alternatively, or additionally, this may be achieved by applying a low friction coating to the sliding layer 6, and / or applying a lubricant to the sliding layer 6.

[0105] Alternatively or additionally, friction reducing means, to reduce the friction at the sliding interface, may be provided by forming the energy absorbing layer 3 from a low friction material, by applying a low friction coating to the energy absorbing layer 3, and / or applying a lubricant to the energy absorbing layer 3. The helmet 1 shown in Fig. 2 also comprises connectors 5 attached to each independent section of the interface layer 4. The connectors 5 are also attached to the sliding layer 6 to allow relative sliding between the energy absorbing layer 3 and the sections of the interface layer 4. Alternatively or additionally, one or more of the connectors 5 may be connected to another part of the remainder of the helmet 1, such as the energy absorbing layer 3 or the outer layer 2. The connectors 5 may also be connected to two or more parts of the remainder of the helmet 1.

[0106] It should be understood that such an arrangement of the energy absorbing layer 3 and the interface layer 4 may be added to any helmet described herein.

[0107] Fig. 3 shows a helmet 1 comprising an outer layer 2, an energy absorbing layer 3 and an interface layer 4. The interface layer 4 is provided as a single layer and comprises comfort padding 4A attached to a substrate 4B. The substrate 4B may be bonded to the outer side of the comfort padding 4A. Such bonding could be through any means, such as by adhesive or by high frequency welding or stitching.

[0108] The helmet 1 of Fig.3 is configured such that the interface layer 4 is able to slide relative to the energy absorbing layer 3 in response to an impact. A sliding interface is provided between the interface layer 4 and the energy absorbing layer 3.

[0109] The substrate 4B of the interface layer 4 faces the sliding interface. The substrate 4B may be formed from a relatively hard material, e.g. relative to the energy absorbing layer 3 and / or the comfort padding 4A. The substrate 4B is configured to provide friction reducing means to reduce the friction at the sliding interface. This may be achieved by forming the substrate 4B from a low friction material, such as PC, PTFE, ABS, PVC, Nylon, PF A, FEP, PE and UHMWPE. Alternatively, or additionally, this may be achieved by applying a low friction coating to the substrate 4B, and / or applying a lubricant to the substrate 4B. In an alternative example, the substrate 4B may be formed from a fabric material, optionally coated with a low friction material.

[0110] Alternatively or additionally, friction reducing means, to reduce the friction at the sliding interface, may be provided by forming the energy absorbing layer 3 from a low friction material, by applying a low friction coating to the energy absorbing layer 3, and / or applying a lubricant to the energy absorbing layer 3.

[0111] The helmet 1 shown in Fig. 3 also comprises connectors 5 attached to the interface layer 4. The connectors are also connected to the energy absorbing layer to allow relative sliding between the energy absorbing layer 3 and the interface layer 4. Alternatively, or additionally, one or more of the connectors 5 may be connected to another part of the remainder of the helmet 1, such as the outer layer 2. The connectors 5 may also be connected to two or more parts of the remainder of the helmet 1

[0112] It should be understood that such an arrangement of the energy absorbing layer 3 and the interface layer 4 may be added to any helmet described herein.

[0113] Fig. 4 shows a helmet 1 comprising an outer layer 2, an energy absorbing layer 3 and an interface layer 4. The interface layer 4 is provided as a plurality of independent sections each comprising comfort padding 4A attached to a substrate 4B. The substrate 4B may be bonded to the outer side of the comfort padding 4A. Such bonding could be through any means, such as by adhesive or by high frequency welding or stitching.

[0114] The helmet 1 of Fig. 4 is configured such that the interface layer 4 is able to slide relative to the energy absorbing layer 3 in response to an impact. A sliding interface is provided between the interface layer 4 and the energy absorbing layer 3.

[0115] The substrate 4B of the sections of the interface layer 4 faces the sliding interface. The substrate 4B may be formed from a relatively hard material, e.g. relative to the energy absorbing layer 3 and / or the comfort padding 4A. The substrate 4B is configured to provide friction reducing means to reduce the friction at the sliding interface. This may be achieved by forming the substrate 4B from a low friction material, such as PC, PTFE, ABS, PVC, Nylon, PF A, FEP, PE and UHMWPE. Alternatively, or additionally, this may be achieved by applying a low friction coating to the substrate 4B, and / or applying a lubricant to the substrate 4B. In an alternative example, the substrate 4B may be formed from a fabric material, optionally coated with a low friction material.

[0116] Alternatively or additionally, friction reducing means, to reduce the friction at the sliding interface, may be provided by forming the energy absorbing layer 3 from a low friction material, by applying a low friction coating to the energy absorbing layer 3, and / or applying a lubricant to the energy absorbing layer 3.

[0117] The helmet 1 shown in Fig. 4 also comprises connectors 5 attached to the sections of the interface layer 4. The connectors 5 are also connected to the energy absorbing layer 3 to allow relative sliding between the energy absorbing layer 3 and the interface layer 4. Alternatively, or additionally, one or more of the connectors 5 may be connected to another part of the remainder of the helmet 1, such as the outer layer 2. The connectors 5 may also be connected to two or more parts of the remainder of the helmet 1

[0118] It should be understood that such an arrangement of the energy absorbing layer 3 and the interface layer 4 may be added to any helmet described herein.

[0119] Fig. 5 shows a helmet 1 comprising an outer layer 2 and an energy absorbing layer 3. Although not shown, an interface layer may additionally be provided.

[0120] The helmet 1 of Fig. 5 is configured such that the outer layer 2 is able to slide relative to the energy absorbing layer 3 in response to an impact. A sliding interface may be provided between the outer layer 2 and the energy absorbing layer 3

[0121] Although not shown, an additional layer may be provided on a surface of the energy absorbing layer 3 facing the sliding interface. The additional layer may be moulded to the energy absorbing layer 3 or otherwise attached thereto. The additional layer may be formed from a relatively hard material, e.g. relative to the energy absorbing layer 3. The additional layer may be configured to provide friction reducing means to reduce the friction at the sliding interface. This may be achieved by forming the additional layer from a low friction material, such as PC, PTFE, ABS, PVC, Nylon, PF A, FEP, PE and UHMWPE. Alternatively, or additionally, this may be achieved by applying a low friction coating to the additional layer and / or applying a lubricant to the additional layer.

[0122] Alternatively or additionally, friction reducing means, to reduce the friction at the sliding interface, may be provided by forming the outer layer 2 from a low friction material, providing an additional low friction layer on a surface of the outer layer 2 facing the sliding interface, by applying a low friction coating to the outer layer 2, and / or applying a lubricant to the outer layer 2.

[0123] The helmet 1 shown in Fig. 5 also comprises connectors 5 attached to the outer layer 2. The connectors 5 are also attached to the energy absorbing layer 3 (or additional layer) to allow relative sliding between the energy absorbing layer 3 and the outer layer 2. Alternatively or additionally, one or more of the connectors 5 may be connected to another part of the remainder of the helmet 1, such as an interface layer. The connectors 5 may also be connected to two or more parts of the remainder of the helmet 1.

[0124] It should be understood that such an arrangement of the outer layer 2 and the energy absorbing layer 3 may be added to any helmet described herein.

[0125] Fig. 6 shows a helmet 1 comprising an outer layer 2 and an energy absorbing layer 3. As illustrated, the energy absorbing layer 3 of the helmet shown in Fig. 6 is divided into outer and inner parts 3A, 3B. Although not shown, an interface layer may additionally be provided.

[0126] The helmet 1 of Fig. 6 is configured such that the outer part 3 A of the energy absorbing layer 3 is able to slide relative to the inner part 3B of the energy absorbing layer 3 in response to an impact. A sliding interface may be provided between the outer part 3A of the energy absorbing layer 3 and the inner part 3B of the energy absorbing layer 3.

[0127] Although not shown, an additional layer may be provided on a surface of one or both of the inner and outer parts 3A, 3B of the energy absorbing layer 3 facing the sliding interface. The additional layer may be moulded to the inner or outer parts 3A, 3B of the energy absorbing layer 3 or otherwise attached thereto. The additional layer may be formed from a relatively hard material, e.g. relative to the energy absorbing layer 3. The additional layer may be configured to provide friction reducing means to reduce the friction at the sliding interface. This may be achieved by forming the additional layer from a low friction material, such as PC, PTFE, ABS, PVC, Nylon, PF A, FEP, PE and UHMWPE.

[0128] Alternatively, or additionally, this may be achieved by applying a low friction coating to the additional layer and / or applying a lubricant to the additional layer. Alternatively or additionally, friction reducing means, to reduce the friction at the sliding interface, may be provided by forming one or both of the inner and outer parts 3 A, 3B of the energy absorbing layer 3 from a low friction material, providing an additional low friction layer on a surface of the inner and outer parts 3A, 3B of the energy absorbing layer 3 facing the sliding interface, by applying a low friction coating to the inner and outer parts 3 A, 3B of the energy absorbing layer 3, and / or applying a lubricant to the inner and outer parts 3 A, 3B of the energy absorbing layer 3.

[0129] The helmet 1 shown in Fig. 6 also comprises connectors 5 attached to the inner part 3B of the energy absorbing layer 3 (or additional layer). The connectors 5 are also attached to the outer part 3A of the energy absorbing layer 3 (or additional layer) to allow relative sliding between the inner part 3B of the energy absorbing layer 3 and the outer part 3A of the energy absorbing layer 3. Alternatively or additionally, one or more of the connectors 5 may be connected to another part of the remainder of the helmet 1, such as an interface layer. The connectors 5 may also be connected to two or more parts of the remainder of the helmet 1.

[0130] It should be understood that such an arrangement of inner and outer parts 3 A, 3B of the energy absorbing layer 3 may be added to any helmet described herein.

[0131] Fig. 11 shows a helmet 1 substantially the same as the helmet 1 shown in Fig. 6. However, in the helmet of Fig. 11, the inner part 3B of the energy absorbing layer 3 is formed in multiple parts 3C and 3D adjacent each other in the circumferential direction of the helmet. These parts 3C and 3D are configured to move relative to each other, as well as to the outer part 3 A of the energy absorbing layer. The parts 3C and 3D may be connected to each other by one or more connectors that allow their relative movement.

[0132] Fig. 7 shows a helmet 1 comprising an outer layer 2 and an energy absorbing layer 3. As shown in Fig. 7, one or more outer plates 7 are mounted to the outer layer 2 of the helmet 1. The outer plates 7 may be formed from a relatively strong and / or rigid material, for example from the same types of materials as from which the outer layer 2 may be formed. Although not shown, an interface layer may additionally be provided.

[0133] The helmet 1 of Fig. 7 is configured such that the outer plates 7 are able to slide relative to the outer layer 2 in response to an impact. A sliding interface may be provided between the outer plates 7 and the outer layer 2.

[0134] Friction reducing means, to reduce the friction at the sliding interface, may be provided by forming the outer layer 2 and / or the outer plates 7 from a low friction material, providing an additional low friction layer on a surface of the outer layer 2 and / or the outer plates 7 facing the sliding interface, by applying a low friction coating to the outer layer 2 and / or the outer plates 7, and / or applying a lubricant to the outer layer 2 and / or the outer plates 7.

[0135] The helmet 1 shown in Fig. 7 also comprises connectors 5 attached to the outer plates 7 The connectors 5 are also attached to the outer layer 2 to allow relative sliding between the plates 7 and the outer layer 2. Alternatively or additionally, one or more of the connectors 5 may be connected to another part of the remainder of the helmet 1, such as the energy absorbing layer 3. The connectors 5 may also be connected to two or more parts of the remainder of the helmet 1.

[0136] In such an arrangement, in the event of an impact on the helmet 1, it can be expected that the impact would be incident on one or a limited number of the outer plates 7. Therefore, by configuring the helmet such that the one or more outer plates 7 can move relative to the outer layer 2 and any outer plates 7 that have not been subject to an impact, the surface receiving the impact, namely one or a limited number of outer plates 7, can move relative to the remainder of the helmet 1. In the case of an impact, this may reduce the rotational acceleration of the head of a wearer.

[0137] It should be understood that such an arrangement of outer plates 7 may be added to any helmet described herein, namely an arrangement having a sliding interface between at least two of the layers of the helmet 1.

[0138] Some helmets, such as those shown in Figs. 1 to 6, are configured to cover a top portion of the head and the above described helmet structures are appropriately located in the helmet to cover a top portion of the head. For example, a helmet may be provided to substantially cover the forehead, top of the head, back of the head, and / or temples of the wearer. The helmet may substantially cover the cranium of the wearer. Some helmets may be configured to cover other parts of the head, alternatively or additionally to a top portion. For example, helmets such as the helmet shown in Fig. 8 may cover the cheeks and / or chin of the wearer. Such helmets may be configured to substantially cover the jaw of the wearer. Helmets of the type shown in Fig. 8, are often referred to as full-face helmets. As shown in Fig. 8, cheek pads 30 may be provided on either side of the helmet 1 (i.e. left and right sides). The cheek pads 30 may be arranged within an outer layer 2 of the helmet 1 to protect the side of the face of the wearer from an impact.

[0139] The cheek pads 30 may have the same layered structure as the example helmets described above. For example, the cheek pads 30 may comprise one or more energy absorbing layers as described above, and / or an interface layer as described above, and / or layers that move relative to each other as described above, optionally, layers may be connected by connectors as described above. Alternatively or additionally, the cheek pads 30 themselves may be configured to move relative to the outer layer 2 and, optionally be connected to the outer layer by connectors as described above.

[0140] Although, the above examples relate to helmets, as stated above, the disclosure may also relate to alternative protective apparel, such as body armour, as shown in Figs. 9 and 10. Body armour 100 may provide protection for other parts of the body, such as the shins, knees, thighs, forearms, elbows, upper arms, shoulders, chest, and back. Individual items of body armour may be provided to protect individual body parts (as shown in Fig. 9), or alternatively may be combined in apparel comprising multiple armoured regions 101 to protect more than one body part (as shown in Fig. 10). Such body armour 100 may be worn for the same activities as helmets, discussed above, including for combat, sports, and motorcycling.

[0141] The body armour 100 may have the same layered structure as the example helmets described above. For example, the body armour 100 may comprise an outer layer 2 as described above, one or more energy absorbing layers 3 as described above, and / or an interface layer as described above, and / or layers that move relative to each other as described above, and / or layers may be connected by connectors 5 as described above.

[0142] General features of a different type of helmet from those described with reference to Figs. 1 to 8 and 11 will now be described with reference to Figs. 12 and 13.

[0143] Helmets of the type described with reference to Figs. 12 and 13 have an outer layer (or outer shell) 2, which may have any of the features, in any combination, of the outer layer 2 described above with respect to Figs. 1 to 7 and 11. Helmets of the type described with reference to Figs. 12 and 13 may also have outer plates as described with reference to Fig. 7.

[0144] Helmets of the type described with reference to Figs. 12 and 13 may also have an energy absorbing layer 3, which may have any of the features, in any combination, of the energy absorbing layer 3 described above with respect Figs. 1 to 7 and 11. Where used, the layer of energy absorbing material may be provided as a shell over substantially all of the surface of the hard shell facing the wearer’s head, although ventilation holes may be provided. Alternatively or additionally, localised regions of energy absorbing material may be provided between the hard shell and a head mount (described below). For example, a band of energy absorbing material may be provided around a circumference of the wearer’s head (such as around the lower edge of the outer shell) and / or a section of energy absorbing material may be provided to be located above the top of the wearer’s head.

[0145] Fig. 12 schematically depicts a cross-section of a helmet of a different type from those depicted in Figs. 1 to 7 and 11. Fig. 12 shows an example helmet 1 comprising a head mount 20. Although not shown in Figs. 1 to 7 and 11, these example helmets may also comprise a head mount 20. The head mount 20 may be provided to mount the helmet 1 on the head of a wearer. In some arrangements, this may improve the comfort of the wearer.

[0146] The head mount 20 may be provided in any form that can function to contribute to mounting the helmet to the wearer’s head. In some configurations, it may assist in securing the helmet 1 to the wearer’s head but this is not essential. The head mount 20 may be configured to at least partially conform to the head of the wearer. For example, the head mount 20 may be elasticated and / or may comprise an adjustment mechanism for adjusting the size of the interface layer. In an arrangement, the head mount 20 may engage with the top of a wearer’s head. The head mount 20 may be removable. This may enable the head mount 20 to be cleaned and / or may enable the provision of an interface layer that is configured to fit a specific wearer.

[0147] As shown in Fig. 12, the head mount 20 is suspended within the rest of the helmet, e.g. a cavity formed therein for accommodating the head, (e.g. the outer shell 2 and / or optional energy absorbing layer 3) such that an air gap 21 is provided between the rest of the helmet and the head mount 20. The head mount 20 may be connected to the rest of the helmet (e.g. to the outer shell 2 and / or optional energy absorbing layer 3) by connectors 25. Helmets of this type are commonly used for industrial purposes, such as by builders, mineworkers or operators of industrial machinery. However, helmets based on such an arrangement may be used for other purposes.

[0148] In a helmet 1 such as that depicted in Fig. 12, the provision of an air gap 21 between the inner surface of the outer shell 2 and the head mount 20 is intended to ensure that loading caused by an impact on the outer shell 2 is spread across a wearer’s head. In particular, the load is not localised on a point on the wearer’s head adjacent the point of impact on the helmet 1. Instead, the load is spread across the outer shell 2 and, subsequently, spread across the head mount 20 and therefore spread across the wearer’s skull.

[0149] During an impact, some of the energy of the impact may be absorbed by deformation of parts of the helmet, such as the head mount, reducing the size of the air gap. Accordingly, the size of the air gap 21 between the outer shell 2 and the head mount 20 may be chosen to ensure that, under an impact on the helmet below a threshold force that the helmet is designed to withstand, the head mount 20 does not come into contact with the outer shell 2, namely the air gap 21 is not entirely eliminated, such that the impact may be directly transferred from the hard shell to the head mount 20. However, in some example helmets, for impacts above the threshold force, the gap 21 may be eliminated, e.g. at a specification location such as the location of impact, such that the rest of the helmet contacts the head mount 20. Such example helmets may comprise an energy absorbing layer 3, which is provided in the space that would otherwise be empty and forming the air gap 21 In other words, part of the air gap 21 may be replaced by an energy absorbing layer. This may bring the rest of the helmet closer to the head mount 20. In an arrangement, the helmet 1 may be configured such that, in the absence of an impact on the helmet, the separation between the outer shell 2 and the head mount 20 at a location corresponding to the top of the head of a wearer is at least 10 mm, optionally at least 15 mm, optionally at least 20 mm, optionally at least 30 mm, optionally at least 40 mm. The magnitude of the impact that the helmet 1 is designed to withstand, and therefore the size of the air gap 21, may depend upon the intended use of the helmet 1. It should be understood that, depending on the intended use of the helmet the size of the air gap 21 may be different at different locations. For example, the air gap 21 may be smaller at the front, back or side of the helmet than it is at the location corresponding to the top of the head of the wearer.

[0150] In arrangements that include an energy absorbing layer, the energy absorbing layer may contribute to the helmet’s ability to withstand radial impacts. In particular in arrangements in which the energy absorbing material is located within the air gap between the outer shell 2 and the head mount 20 at the location corresponding to the top of the wearer’s head, it will be appreciated that the gap between the head mount and the surface of the energy absorbing layer will be smaller than the gap between the outer shell and the head mount, and may be eliminated altogether. Additionally, as a result of the energy absorbing material’s contribution in the event of a radial impact, a smaller gap between the outer shell and the head mount may be required than would be the case in the absence of the energy absorbing material.

[0151] In some arrangements, the head mount 20 may include a head band, or head ring, that at least partially surrounds the wearer’s head. Alternatively or additionally, the head mount 20 may include one or more straps that extend across the top of the wearer’s head. Alternatively or additionally, the head mount 20 may include a cap or shell that encapsulates an upper portion of the wearer’s head. Straps or bands that form part of the head mount may be formed from Nylon fabric. Straps or bands that form part of the head mount may be formed from plastics (non-fabric) materials. Other materials may alternatively or additionally be used.

[0152] Fig. 13 shows an example helmet of the type schematically depicted in Fig. 12. As shown, the head mount includes a plurality of straps 31 that extend across the top of the head of a wearer of the helmet 1. The straps 31 may be connected at connection points to the outer shell 2 by any of a plurality of known methods. For example, the outer shell 2 may be moulded to include sockets into which connectors 25 may be inserted.

[0153] In the arrangement depicted in Fig. 13, the head mount 20 is formed from two straps 31 that each extend between a pair of connectors 25 positioned such that the straps 31 extend across the head of the wearer of the helmet. For example, a first strap 31 may extend from a rear left position to a forward right position and a second strap 31 may extend from a rear right position to a forward left position. However, it should be appreciated that many other arrangements may be used. For example, additional straps may be provided, such that there are three, four or more straps extending across the top of the head of the wearer. An additional strap may be provided extending from left to right. A further additional strap may be provided extending from front to back. Similarly, the position of the connection points of the straps 31 to the remainder of the helmet 1 may be different from that depicted in Fig. 13.

[0154] In an arrangement where different straps 31 are in proximity to each other, for example, at the top of the wearer’s head, the straps 31 may not be connected to each other, permitting some movement of one strap relative to another. In other arrangements, the straps 31 may be connected to each other where they cross. In a further arrangement, the head mount may include one or more straps that extend from a connection point to the remainder of the helmet 1 to a point at which it is connected to other straps, for example, at a location corresponding to the top of the head of a wearer of the helmet. Finally, as noted above, in other arrangements, the head mount may be formed from components other than straps, for example from a cap or shell that can be mounted to the top of the head of the wearer of the helmet 1.

[0155] As shown in Fig. 13, the head mount may include a head ring (or headband) 30. The head ring 30 may surround, and engage with, a circumference of the head of the wearer, as shown in Fig. 10. Alternatively, the head ring may engage at least the forehead of a wearer of the helmet and may surround a portion of the head of the wearer. It should be appreciated that such a head ring 30 may be connected to the helmet 1 separately from the remainder of the head mount, such as straps 31. Alternatively, the head ring 30 may be connected to the helmet 1 by means of the straps 20. As a further alternative, the straps 20 may be connected to the rest of the helmet 1 by means of the head ring 30. Further straps, e.g. chin straps, may be provided to secure the helmet 1 to the head of the wearer.

[0156] The present disclosure specifically relates to helmets (or other protective apparel) comprising a sliding interface between an interface layer 4 and an outer part of the helmet. More specifically, the interface layer 4 is a comfort padding inner layer comprising a layer of compressible material configured to provide cushioning for comfort and or fitting of the helmet to a wearer.

[0157] The outer part of the helmet may refer to one or more parts of the helmet outward of the interface layer. In most cases, there are no parts more inward than the interface layer 4, so the outer part of the helmet will form the rest of the helmet. Typically, the outer part of the helmet will comprise one or both of an energy absorbing layer 3 and an outer layer 2 (e.g. an outer shell). Such a helmet may be of the type shown in, and described above in relation to, Figs. 1 to 4, for example.

[0158] Fig. 14 illustrates the layered construction of the comfort padding layer 4 prior to processing steps attaching the layers to form the comfort padding layer 4. As shown in fig. 14, the comfort padding layer 4 comprises the compressible material 40 and a backing layer 41. As shown, an optional covering layer 42 is provided on the other side of the compressible material 40 to the backing layer 41.

[0159] To form the comfort padding layer 40, the layer of compressible material 40, backing layer 41 and optional covering layer 42 may be attached together. As shown in Fig. 15, in one example, these layers may be compressed and / or welded together. Although Fig. 15 seems to depict that the compressible material may be arranged only between the compressed and / or welded portions, in fact the compressible material may also be compressed and / or welded at the compressed and / or welded portions. In some examples, some portions of the compressible material 40, namely the uncompressed portions, may be configured to provide the cushioning function. Other portions of the compressible material 40, namely the compressed portions, may not be configured to provide any cushioning function, or any substantial cushioning function. The compressible material 40 may be formed from a relatively low-density foam material, such as polyurethane (PU) foam or polyethylene (PE) foam. The covering layer may be formed from a fabric material. The fabric material of the covering layer may be a mesh fabric, for example. The function of the covering layer 42 may be to retain the compressible material to improve the integrity of the comfort padding layer 4 and / or further improve comfort.

[0160] When used within the helmet, the backing layer 41 is configured to face an inner surface (i.e. inward facing surface) of the outer part of the helmet. For simplicity, the following description will assume that this outer part of the helmet is an energy absorbing layer 3. The backing layer 41 is further configured to slide relative to the inner surface of the energy absorbing layer 3 in response to an oblique impact to the energy absorbing layer 3. Accordingly, the comfort padding layer 4 can move relative to the energy absorbing layer 3. A low friction sliding interface may be provided between the backing layer 3 and the inner surface of the energy absorbing layer 3, e.g. as described above.

[0161] The backing layer 41 may be configured to be attached to the energy absorbing layer 3, e.g. the inner surface thereof, at one or more attachment points 43 of the backing layer 41. Corresponding attachment points may be provided to the energy absorbing layer 3.

[0162] In one specific example, the attachment points 43 may comprise hook and loop attachment means, e.g. looped parts formed by brushed nylon. In such an example, the backing layer 42 may be formed from brushed nylon such that the looped parts face towards the energy absorbing layer. The corresponding attachment parts of the energy absorbing layer 3 may comprise the hooked parts of the hook and loop attachment means. Alternatively, attachment points may comprise attachment means in the form of adhesive patches, mechanical connectors or otherwise.

[0163] The backing layer 41 may be configured to be detachably attached to the energy absorbing layer 3 at the one or more attachment points. Accordingly, the attachment means may be configured to detach, e g. above a threshold shearing displacement and / or force between the comfort padding layer 4 and the energy absorbing layer 3. For example, the hook and loop parts described above may detach from each other. As shown in Figs 14 and 15, the comfort padding layer 4 may additionally comprise a stiffening layer 44 configured to provide increased stiffness to the comfort padding layer at least at the one or more portions of the comfort padding layer 4 corresponding to the attachment points 43, compared to when the stiffening layer 44 is absent. Accordingly, the stiffening layer 44 is provided at least at the one or more portions of the comfort padding layer 4 corresponding to the attachment points 43. In some examples, the stiffening layer 44 may be provided in a region adjacent each attachment point 43. This region may be directly adjacent an attachment point 43, or may alternatively or additionally surround a region directly adjacent the attachment point 43, but still be substantially adjacent the attachment point 43. In some examples, the stiffening layer 44 may be provided within a predefined distance of an attachment points 43 that is less than the displacement expected or permitted in response to an oblique impact. In some, examples the stiffening layer may additionally be provided in a region that is not adjacent an attachment point. In some examples, the stiffening layer 44 may be provided substantially throughout the entire comfort padding layer 4.

[0164] A purpose of the stiffening layer is to provide increased stiffness to the comfort padding layer in order to facilitate relative sliding between the backing layer and the inner surface of the energy absorbing layer in response to an oblique impact to the helmet. The stiffening layer 44 may facilitate detachment of the attachment points 43 from the energy absorbing layer 3 in response to an oblique impact to the helmet, to enable the backing layer 41 to slide relative to the inner surface of the energy absorbing layer 3 in response to an oblique impact to the helmet.

[0165] The layer of compressible material 40, the backing layer 41 and optional covering layer 42 may be flexible and able to substantially conform to the shape of the inner surface of the energy absorbing layer 3 and / or the wearer. Preferably, the stiffening layer 42 is also formed such that the comfort padding layer 4 is flexible and able to substantially conform to the shape of energy absorbing layer 3 and / or the wearer. Preferably, the stiffening layer 44 is configured so as to not substantially increase the bending stiffness of the backing layer 41, compared to when the stiffening layer is absent. Preferably, the stiffening layer 44 is configured to provide increased tensile stiffness to the backing layer 41, compared to when the stiffening layer is absent, in order to reduce stretching of the backing layer 41 and / or layer of compressible material 40 resulting from a tangential force at the one or more atachment points, under an impact. In some examples, the stiffening layer may locally increase the bending stiffness of the comfort padding layer 4, e.g. at a portion corresponding to an attachment device. In such examples, the overall bending stiffness of the comfort padding may still be such that the comfort padding layer 4 is flexible and able to substantially conform to the shape of energy absorbing layer 3 and / or the wearer.

[0166] As shown in Fig. 15, the stiffening layer 44 may be attached, and preferably immovably fixed, to the backing layer, e.g. welded thereto during formation of the comfort padding layer 4. As shown, the stiffening layer 44 may be provided on an inner side of the backing layer 41, on an opposite side to the energy absorbing layer 3, when the comfort padding layer 4 is used within a helmet. The stiffening layer 44 may be provided substantially over all of the backing layer 41. In some examples, the stiffening layer 44 may be attached, e.g. immovably, to the backing layer 41 at one or more specific portions. In some examples, at other portions, the stiffening layer 44 may not be attached to the backing layer 41. At these other portions, some movement between the stiffening layer 44 and the backing layer 41 may be permitted.

[0167] The stiffening layer 44 may comprise treated and untreated portions. The stiffness of the treated portions may be greater than the stiffness of the untreated portions. The treated portions may refer to portions of the stiffening layer 44 that have been subject to one or more additional processing steps compared to untreated portions. These one or more additional processing steps may be performed at any stage during the manufacture process. The treated portions may be treated by heat and / or friction, for example. The treated portions may be treated using a high frequency welding process, in some examples. Other examples of treatment may include pressure, chemical treatment (e g. chemical based welding), or the application of a coating (e.g. an adhesive).

[0168] The treated portions of the stiffening layer 44 may bond the stiffening layer 44 to the backing layer and / or the layer of compressible material 40. The treated portions may be formed during a manufacturing step of welding layers of the comfort padding layer 4 together. The attachment points may be exclusively arranged at locations corresponding to the untreated portions. Accordingly, the comfort padding layer 4 may be attached to the energy absorbing layer 3 at locations corresponding to the untreated portions but not the treated portions. The stiffening layer 44 is preferably formed from a synthetic polymer material, such as polyethylene. Alternatively, a natural (e.g. cellulose-based) polymer may be used. The stiffening layer may be formed from a woven or non-woven (e.g. spunbond) fabric material. The stiffening layer may be formed from a breathable material. The breathability of treated portions may be lower than the breathability of the untreated portions. In one example, the stiffening layer 44 is formed from a spunbond polyethylene fibre material, such as DuPont™ Tyvek™. In some examples, the stiffening layer may comprise perforations to provide breathability.

[0169] Figs. 14 and 15 show an example comfort padding layer 4 formed from a mesh fabric covering layer, a foam layer of compressible material, a woven polyethylene fibre material stiffening layer and a brushed nylon backing layer in order. To form the comfort padding layer 4, these layers are compressed and welded together, e.g. by high frequency welding, at attachment portions as indicated in Fig. 15. At these welded portions, by means of the welding step, the stiffening layer is treated so as to have increased stiffness relative to the non-welded portions. The attachment points may be provided at nontreated portions, e g. surrounded by the treated portions, as shown in Fig. 15. In some examples, the stiffening layer 44 may only be provided at the welding portions. In such an example, the stiffening layer 44 would only comprise treated portions, which correspond to the welded portions.

[0170] The materials forming the layers of the comfort padding layer 4 may be provided as sheets, arranged one on top of the other, then welded and cut out to form the comfort padding layer 4.

[0171] In alternative examples, the backing layer 41 may not be formed from a layer of material attached to the other layers, but instead may be a layer applied to the surface of the stiffening layer. For example, the backing layer may be formed from a varnish or lacquer, formed from a low friction material, as described above. Accordingly, for example, a covering layer, layer of compressible material and stiffening layer may be formed as described above, then the backing layer may be applied.

[0172] Helmets as described above may be used in various activities. These activities include combat and industrial purposes, such as protective helmets for soldiers and hard-hats or helmets used by builders, mine-workers, or operators of industrial machinery for example. Helmets, are also common in sporting activities. For example, protective helmets may be used in ice hockey, cycling, motorcycling, motor-car racing, skiing, snow-boarding, skating, skateboarding, equestrian activities, American football, baseball, rugby, soccer, cricket, lacrosse, climbing, golf, airsoft, roller derby, and paintballing.

[0173] Examples of injuries that may be prevented or mitigated by the helmets described above include Mild Traumatic Brain Injuries (MTBI) such as concussion, and Severe Traumatic Brain Injuries (STB I) such as subdural haematomas (SDH), bleeding as a consequence of blood vessels rapturing, and diffuse axonal injuries (DAI), which can be summarized as nerve fibres being over stretched as a consequence of high shear deformations in the brain tissue.

[0174] Depending on the characteristics of the rotational component of an impact, such as the duration, amplitude and rate of increase, either concussion, SDH, DAI or a combination of these injuries can be suffered. Generally speaking, SDH occur in the case of accelerations of short duration and great amplitude, while DAI occur in the case of longer and more widespread acceleration loads.

[0175] Variations of the above described examples are possible in light of the above teachings. It is to be understood that the invention may be practiced otherwise and specifically described herein without departing from the spirit and scope of the invention.

Claims

CLAIMS1. A comfort padding layer for use within protective apparel, comprising: a layer of compressible material configured to provide cushioning for comfort and / or fitting of the protective apparel to a wearer; a backing layer attached to the layer of compressible material, wherein the backing layer is configured, when used within the protective apparel, to face an inner surface of an outer part of the protective apparel and slide relative to the inner surface in response to an oblique impact to the outer part of the protective apparel, such that the comfort padding layer can move relative to the outer part of the protective apparel; one or more attachment points, provided on the backing layer, at which the backing layer is configured to be detachably attached to the outer part of the protective apparel; a stiffening layer, provided at least at one or more portions of the backing layer corresponding to the one or more attachment points, configured to provide increased stiffness to the comfort padding layer in order to facilitate relative sliding between the backing layer and the inner surface of the outer part of the protective apparel in response to an oblique impact to the protective apparel.

2. The comfort padding layer of claim 1, wherein the stiffening layer is configured to facilitate detachment of the attachment points from the outer part of the protective apparel in response to an oblique impact to the helmet, to enable relative sliding between the backing layer and the inner surface of the outer part of the protective apparel in response to an oblique impact to the protective apparel.

3. The comfort padding layer of claim 1 or 2, wherein the stiffening layer is formed such that the comfort padding layer is flexible and able to substantially conform to the shape of the inner surface of the outer part of the protective apparel and / or the wearer.

4. The comfort padding layer of any preceding claim, wherein the stiffening layer is configured to provide increased tensile stiffness to the backing layer in order to reduce stretching of the backing layer resulting from a tangential force at the one or more attachment points.

5. The comfort padding layer of any preceding claim, wherein the stiffening layer is configured so as to not substantially increase the bending stiffness of the backing layer.

6. The comfort padding layer of any preceding claim, wherein the backing layer is formed from a soft material.

7. The comfort padding layer of any preceding claim, wherein the stiffening layer is immovably fixed to the backing layer.

8. The comfort padding layer of any preceding claim, wherein the stiffening layer is provided on an inner side of the backing layer, on an opposite side to the outer part of the protective apparel when the comfort padding inner layer us used within the protective apparel.

9. The comfort padding layer of any preceding claim, wherein the stiffening layer extends over substantially all of the backing layer.

10. The comfort padding layer of any preceding claim, wherein the stiffening layer is formed from a synthetic polymer material.

11. The comfort padding layer of any preceding claim, wherein the stiffening layer is formed from a non-woven fabric material.

12. The comfort padding layer of any preceding claim, wherein the stiffening layer is formed from a spunbond polyethylene fibre material.

13. The comfort padding layer of any preceding claim, wherein the stiffening layer is formed from a breathable material.

14. The comfort padding layer of any preceding claim, wherein the stiffening layer comprises treated and untreated portions, wherein the stiffness of the treated portions is greater than the stiffness of the untreated portions.

15. The comfort padding layer of claim 14, wherein the breathability of the untreated portions is higher than the breathability of the treated portions.

16. The comfort padding layer of claim 14 or 15, wherein the treated portions are provided to surround the untreated portions, and are provided at portions corresponding to the compressible material configured to provide cushioning.

17. The comfort padding layer of any one of claims 14 to 16, wherein the attachment points are arranged at locations corresponding to the untreated portions.

18. The comfort padding layer of any one of claims 14 to 17, wherein the treated portions are treated with heat and / or pressure and / or chemical treatment and / or application of a coating.

19. The comfort padding layer of any one of claims 14 to 18, wherein the treated portions of the stiffening layer bond the stiffening layer to the backing layer and / or the layer of compressible material.

20. The comfort padding layer of any one of claims 14 to 19, wherein the treated portions are treated using a high frequency welding process.

21. Protective apparel comprising an outer part and a comfort padding layer according to any preceding claim, arranged on an inner side of the outer part closer to a wearer.

22. The protective apparel of claim 21, wherein the outer part comprises an energy absorbing layer and / or an outer shell.

23. The comfort padding or protective apparel of any preceding claim, where in the protective apparel is a helmet.

24. A method of forming the comfort padding of any preceding claim comprising: arranging the layer of compressible material and stiffening layer on top of each other; and welding the layer of compressible material and stiffening layer at one or more attachment portions.

25. The method of claim 24, wherein the backing layer is additionally arranged adjacent the stiffening layer, on an opposite side to the layer of compressible material, and welded.

26. The method of claim 24 or 25, wherein a covering layer is additionally arranged adjacent the layer of compressible material, on an opposite side to the stiffening layer, and welded.

27. The method of any one of claims 24 to 26, wherein the welding step is performed by a high frequency welding process.

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