Sling structure for a protective liner

Abstract

A helmet liner system is provided and includes a sling structure having a sling body with a plurality of pockets connected to one another. Each pocket has one or more segments defining a pocket perimeter, with each pocket being connected to at least one other pocket via at least one connector extending between respective segments. The liner system also includes a protective layer including a plurality of pad clusters made up of a plurality of pads connected to one another. Each pad being adapted to engage respective pockets of the sling structure such that each pad cluster is adapted to cover respective sections of the sling structure. Corresponding manufacturing and assembly methods are also provided.

Description

SLING STRUCTURE FOR A PROTECTIVE LINERTECHNICAL FIELD

[0001] The technical field generally relates to protective gear and equipment, and more specifically relates to a 3D-printed liner system for protective gear and equipment.BACKGROUND

[0002] 3D-printed liner assemblies can include various challenges due to the intricate nature of 3D printing large objects (such as helmet liners). Typically, creating such shapes requires the use of support material, and conventional slicing methods often result in imperfect parts. This occurs because the liner is sliced in layers in a single direction (z- axis), leading to irregularities in the liner components.

[0003] Additionally, traditional methods of fixing the pads of the liner within the shell of the helmet require anchor points at various locations, which can constrain the motion of each pad during impact, thus reducing its effectiveness and comfort.

[0004] While helmets and other protective gear and applications have evolved greatly over the years in an attempt to provide improved protection, there is still a general need for improvements.SUMMARY

[0005] According to an aspect, a helmet liner system for integration within a helmet is provided. The helmet liner system includes a flexible sling structure defining a plurality of pockets, the flexible string structure being configurable between a two-dimensional configuration, where the flexible string structure is adapted to lay substantially flat, and a three-dimensional configuration, where the flexible string structure is adapted to be integrated into a helmet shell; a protective layer including a plurality of pads, each pad being shaped and sized to engage respective pockets of the sling structure, wherein the flexible sling structure is biased from the two-dimensional configuration to the three- dimensional configuration upon engagement of the plurality of pads with the plurality of pockets.

[0006] According to an embodiment, each one of the plurality of pockets includes one or more segments defining a perimeter, and wherein the plurality of pads are each shaped and sized to engage respective pockets within the perimeter.

[0007] According to an embodiment, the perimeter of at least some of the pockets is a closed perimeter.

[0008] According to an embodiment, each pocket of the flexible sling structure is connected to at least one adjacent pocket via one or more pocket connectors.

[0009] According to an embodiment, the pocket connectors extend between and connect adjacent pockets to one another such that the adjacent pockets are spaced from each other by a distance corresponding to a length of the pocket connectors.

[0010] According to an embodiment, the pocket connectors define joints between adjacent pockets enabling relative movement between the pockets.

[0011] According to an embodiment, the pocket connectors and / or the segments of the pockets are at least partially hollow.

[0012] According to an embodiment, the flexible string structure includes a central section, a front section, a back section, a left section and a right section, wherein each section of the flexible string structure includes several pockets.

[0013] According to an embodiment, at least one pocket of the front section is connected to the central section.

[0014] According to an embodiment, at least one pocket of the back section is connected to the central section.

[0015] According to an embodiment, at least one pocket of the left section and the right section is connected to the central section.

[0016] According to an embodiment, the left section is symmetrical with the right section.

[0017] According to an embodiment, each of the front, back, left and rights sections are movable relative to the central section.

[0018] According to an embodiment, each of the front, back, left and rights sections are pivotally movable relative to the central section along respective joints.

[0019] According to an embodiment, the segments of the pockets in different sections of the flexible string structure have respective shapes, sizes and / or configurations.

[0020] According to an embodiment, the segments of the pockets in each section of the flexible string structure have generally the same shape, size and / or configurations.

[0021] The helmet liner system of any one of claims 1 to 16, wherein the flexible string structure is a one-piece unit.

[0022] According to an embodiment, the flexible string structure is a 3D-printed structure.

[0023] According to an embodiment, the plurality of pads of the protective layer includes a plurality of pad clusters connectable to respective sections of the flexible sling structure.

[0024] According to an embodiment, each pad of a common pad cluster is connected to at least one adjacent pad via one or more pad connectors.

[0025] According to an embodiment, the pad connectors extend between and connect adjacent pads to one another such that the adjacent pads are spaced from each other by a distance corresponding to a length of the pad connectors.

[0026] According to an embodiment, the pad connectors define junctions between adjacent pads enabling relative movement between the pads.

[0027] According to an embodiment, the pad connectors and / or the pads are at least partially hollow.

[0028] According to an embodiment, each pad cluster is a one-piece unit.

[0029] According to an embodiment, each pad cluster is a 3D-printed structure.

[0030] According to an embodiment, each pad of the protective layer includes a groove defined about a perimeter thereof shaped and sized to receive the segments of a given pocket of the flexible string structure.

[0031] According to an embodiment, the segments of the pockets and the groove of the pads are configured to cooperate to prevent disconnection between the flexible string structure and the protective layer.

[0032] According to an embodiment, the segments and the grooves have complementary shapes configured to prevent disconnection therebetween.

[0033] According to an embodiment, the segments have a triangular cross-sectional shape.

[0034] According to an embodiment, the groove is a first groove, and wherein one or more pads of the protective layer includes a second groove configured to cooperate with a second flexible string structure.

[0035] According to an embodiment, the second groove is adjacent the first groove.

[0036] According to an embodiment, each pad includes an inner section extending a first side of the groove and an outer section extending on a second side of the groove opposite the inner section, and wherein, upon integration of the helmet liner system in the helmet, the inner section is positioned adjacent a head of a user, and the outer section is positioned adjacent to an inner surface of the helmet.

[0037] According to an embodiment, the pad clusters include a front cluster, a back cluster, a central cluster, a left cluster and a right cluster engageable with the front section, the back section, the central section, the left section and the right section of the flexible string structure, respectively, and wherein at least one section of the flexible string structure includes a connecting pocket configured to engage the pad of an adjacent pad cluster, thereby biasing the flexible string structure towards the three-dimensional configuration.

[0038] According to an embodiment, the helmet liner system further comprises one or more liner anchors configured to enable connection between the assembled flexible string structure and protective layer and the helmet.

[0039] According to an embodiment, each liner anchor includes a liner connector connectable to at least one of the sling structure and the protective layer and a helmet connector connectable to the helmet.

[0040] According to an embodiment, the liner connector includes anchor segments defining an anchor pocket configured to engage at least one of the pads of the protective layer.

[0041] According to an embodiment, the anchor segments have generally the same shape, size and / or configuration as the segments of the pockets of the flexible string structure.

[0042] According to an embodiment, the liner connector is manufactured together with the flexible string structure.

[0043] According to an embodiment, the liner connector is removably connectable to the protective layer.

[0044] According to an embodiment, the helmet connector includes an anchor plate configured to engage an inner surface of the helmet, the anchor plate being configured to be connected to the helmet via one or more mechanical fasteners.

[0045] According to an embodiment, the one or more mechanical fasteners correspond to standard helmet hardware.

[0046] According to another aspect, a helmet liner system is provided and comprises a sling structure having a sling body defining a plurality of pockets, each pocket being connected to at least one adjacent pocket via at least one connector, wherein the sling body is 3D-printed according to a 3D-printing protocol such that each pocket and each connector are created together as part of the 3D-printing protocol and form a continuous one-piece unit; a protective layer including a plurality of pads, each pad being shaped and sized to engage respective pockets of the sling structure.

[0047] According to another aspect, a helmet liner system is provided and comprises a sling structure having a sling body with a plurality of pockets connected to one another, each pocket comprising one or more segments defining a pocket perimeter, each pocket being connected to at least one other pocket via at least one connector extending between respective segments; a protective layer including a plurality of pad clusters made up of a plurality of pads connected to one another, each pad being adapted to engage respective pockets of the sling structure such that each pad cluster is adapted to cover respective sections of the sling structure.

[0048] According to another aspect, a helmet liner system is provided and comprises a sling structure having a sling body having sling sections including a front section, a back section, a right section and a left section, each sling section of the sling body having a plurality of pockets connected to one another; a protective layer including pad clusters made up of a plurality of pads connected to one another, the pad clusters are connectable to respective sling sections, wherein at least one pad of a given pad cluster is connectable to a different sling section to bias the sling body in a shell-shaped configuration for integration in a helmet shell.

[0049] According to another aspect, a helmet comprising a helmet shell defining an inner volume shaped and sized for the integration of the helmet liner system as defined above is provided.

[0050] According to another aspect, a sling structure for supporting protective pads of a helmet liner system is provided. The sling structure includes a sling body defining a plurality of pockets configured to hold respective protective pads, each pocket beingconnected to at least one adjacent pocket via at least one connector, wherein the sling body is 3D-printed according to a 3D-printing protocol, and wherein each pocket and corresponding connector are created together as part of the 3D-printing protocol and form a continuous one-piece unit.

[0051] According to another aspect, a sling structure for supporting protective pads of a helmet liner system is provided. The sling structure includes a flexible sling body defining a plurality of pockets configured to hold respective protective pads, the flexible body being configurable from a two-dimensional configuration, where the flexible body is adapted to lay substantially flat, to a three-dimensional configuration, where the flexible string structure is adapted to be integrated into a helmet shell, upon engagement of the protective pads within respective pockets of the flexible sling body.

[0052] According to another aspect, a method of manufacturing a helmet liner system is provided. The method includes 3D-printing a sling structure having a plurality of pockets connected to one another via at least one connector; 3D-printing a plurality of protective pads adapted to collectively form a protective layer; assembling the protective layer and the sling structure by engaging the plurality of protective pads in respective pockets to form the helmet liner system, wherein assembling the protective layer and the sling structure flexes the sling structure in a predetermined configuration to facilitate integration of the helmet liner system in a helmet shell.

[0053] According to another aspect, a method of manufacturing a helmet liner system is provided. The method includes 3D-printing a sling structure having a plurality of pockets spaced from one another and connected to at least one other pocket via at least one connector by stacking a plurality of layers on each other, wherein each layer is formed of a single continuous string of material such that every pocket of the sling structure is formed simultaneously; 3D-printing a plurality of protective pads adapted to collectively form a protective layer; assembling the protective layer and the sling structure by engaging the plurality of protective pads in respective pockets to form the helmet liner system.

[0054] According to another aspect, a method of manufacturing a sling structure for supporting protective pads of a helmet liner system is provided. The method includes 3D- printing a sling body by stacking a plurality of layers of material on each other, the sling body having a plurality of pockets spaced from one another and connected to at least one other pocket via at least one connector, wherein each layer of material is formed of a single continuous string of material such that the plurality of pockets and each connector is formed together as a one-piece unit.

[0055] According to an embodiment, the method further comprises 3D-printing a frangible connection on top of the sling body; and 3D-printing a second sling body on top of the frangible connection.

[0056] According to an embodiment, a plurality of sling structures are manufactured in a stack of alternating sling bodies and frangible connections.

[0057] According to an embodiment, the sling bodies are adapted to be disconnected from one another by breaking the frangible connection.

[0058] According to an embodiment, the frangible connection is breakable manually.

[0059] According to an embodiment, breaking the frangible connection includes peeling adjacent sling bodies from one another along the frangible connection.

[0060] According to an embodiment, the frangible connection comprises one or more layers of material provided at discreet locations on the previous sling body.

[0061] According to an embodiment, the frangible connection comprises one or more layers of material provided along an entire surface area of the previous sling body.BRIEF DESCRIPTION OF THE DRAWINGS

[0062] Figure 1 is a perspective view of a helmet, according to an embodiment.

[0063] Figure 2 is a perspective view of a helmet liner system adapted to be integrated in the helmet shown in Figure 1, according to an embodiment.

[0064] Figure 3 is a perspective view of the helmet liner system shown in Figure 2, showing additional cheek pads, according to an embodiment.

[0065] Figure 4 is a perspective view of a sling structure of the helmet liner system shown in Figure 2, according to an embodiment.

[0066] Figure 4A is an enlarged view of a section of Figure 4, showing sling pockets connected to one another, according to an embodiment.

[0067] Figure 5 is an enlarged view of a section of the sling structure shown in Figure 4, showing a junction between adjacent sling pockets, according to an embodiment.

[0068] Figures 6 and 7 are perspective views of a plurality of the sling structure shown in Figure 4 manufactured in a stacked configuration, according to an embodiment.

[0069] Figure 8 is a perspective view of the stacked configuration shown in Figures 6 and 7, showing one of the sling structures being manually separated from the stack, according to an embodiment.

[0070] Figure 9 is a top view of a pad cluster of a protective layer of the helmet liner system shown in Figure 2, according to an embodiment.

[0071] Figure 9A is an enlarged view of the pad cluster shown in Figure 9, showing adjacent protective pads connected to one another, according to an embodiment.

[0072] Figure 10 is a front perspective view of the helmet liner system shown in Figure 2, showing the sling structure and the protective layer connected together and in respective 2D configurations, according to an embodiment.

[0073] Figure 11 is a bottom perspective view of the helmet liner system shown in Figure 10, showing the sling structure and the protective layer connected together and in a 3D configuration, according to an embodiment.

[0074] Figure 12 is an enlarged view of a protective pad, showing different sections thereof, including a groove for receiving the sling structure, according to an embodiment.

[0075] Figure 13 is a front perspective view of the helmet liner system shown in Figure 2, showing liner anchors connected to opposite ends thereof, according to an embodiment.

[0076] Figures 14A and 14B are perspective views of a front anchor, according to an embodiment.

[0077] Figures 15A and 15B are perspective views of a back anchor, according to an embodiment.

[0078] Figures 16 and 17 are perspective views of the helmet liner system shown in Figure 2, showing the front anchor connectable with a front section of the helmet liner system, according to an embodiment.

[0079] Figures 18 and 19 are perspective views of the helmet liner system shown in Figures 16 and 17, showing the front anchor in a connection configuration (Figure 18) and showing the helmet liner system integrated in a helmet (Figure 19), according to an embodiment.

[0080] Figures 20 and 21 are perspective views of the helmet liner system shown in Figure 13, showing the back anchor in a connection configuration (Figure 20) and showing the helmet liner system integrated in a helmet (Figure 21), according to an embodiment.

[0081] Figures 22 to 25 are alternative embodiments of the helmet liner system, showing generally round pads.DETAILED DESCRIPTION

[0082] As will be explained below in relation to various embodiments, the present disclosure describes apparatuses, systems and methods for forming protective structures to be implemented into gear and equipment, such as liners for use in helmets, for example. The protective structure can include a support assembly configured to contain and support an array of shock-absorbing pads in order to form the liner. The liner can then be installed within the desired protective gear in order to improve the protection granted by the protective gear.

[0083] More particularly, the present disclosure relates to a helmet liner system formed from a combination of 3D-printed elements. The helmet liner system includes a sling structure shaped and configured to accommodate and provide structural support to a protective layer, such as pads or groups of pads. The sling structure includes a 3D-printed webbed structure defining specific shapes and pockets to enable cooperation with the protective layer. The pads of the protective layer are manufactured individually or in clusters or groups. Each cluster is designed to fit into pockets of the sling structure, and are strategically positioned to provide improved coverage (e.g., of the user’s head and / or of the internal surface of the helmet) and protection. Both the sling structure and clusters of pads are manufactured using 3D-printing technology, and can thus be formed on a flat (e.g., 2D) surface.

[0084] As will be described further below, the sling structure and the pads clusters are configured to interact with each other to seamlessly create a cohesive 3D shape when assembled, thereby forming the helmet liner system (e.g., a liner for integration in a helmet). In other words, the sling structure can be 3D-printed and, when by itself, be adapted to lay flat on a given surface. Upon engaging the clusters of pads into the pockets of the sling structure, the sling structure is biased into a three-dimensional structure. It is thus noted that the assembly of the helmet liner system constrains the sling structure in a 3D configuration. The sling structure can be made of flexible material adapted to allow for some movement of the pads, for example, upon being impacted, thus enhancing the helmet liner system’s effectiveness.

[0085] The assembled liner is connectable to and / or integrates with a helmet shell, providing an advanced protective system. The sling structure’s design also allows for integration with other helmet components, such as sling anchors configured to establish a link between the sling structure and the helmet shell. Overall, the combination of the sling structure, pad clusters, and their interactions / cooperation enables the creation of a versatile and effective helmet liner system, improving protection and comfort for the wearer.

[0086] With reference to Figures 1 to 3, a helmet 10 provided with a helmet liner system 12 according to a possible embodiment is shown. The helmet liner system 12 is configured to be integrated to the helmet 10, and more specifically to an interior of a helmet shell 14. As will be described further below, the helmet liner system 12 is configured to be connected to an inner surface 15 of the helmet shell 14 to provide shock absorption, improve protection and / or improve comfort of the user. In the present disclosure, the helmet 10 is described and illustrated as corresponding to a football helmet, although it should be noted that various other types of helmets can be used with the helmet liner system 12. Similarly, it is noted that other types of equipment can include a liner system similar to that of the helmet liner system 12 described herein. For example, and without being limitative, shoulder pads and / or thigh guards, can be provided with a liner system adapted to improve shock absorption, protection and / or comfort of the user.

[0087] The helmet liner system 12 is adapted to be connected to and engage the inner surface 15 of the helmet shell 14 so as to be positioned between the user’s head and the harder helmet shell 14. In this embodiment, the helmet liner system 12 includes a sling structure 16 and a protective layer 18 configured to cooperate to enable integration with the helmet 12. More specifically, the protective layer 18 includes a plurality of protective pads 20 shaped and sized to engage the sling structure 16. In other words, the sling structure 16 is adapted to provide support to the protective pads 20 to enable positioning the protective pads 20 in predetermined locations relative to one another and / or along the inner surface 15 of the helmet shell 14. In addition, the sling structure 16 is adapted to be connected to the inner surface 15 of the helmet shell 14, thereby securing the helmet liner system 12 within the cavity of the helmet 10.Sling structure

[0088] Now referring to Figures 4 to 5, in addition to Figure 1 to 3, the sling structure 16 includes a sling body 21 made up of a plurality of interconnected pockets 22. In some embodiments, each pocket 22 has a pocket perimeter 24 defined by one or more segments 26. In this embodiment, the segments 26 have a truss-like structure to increaserigidity of the segment 26, while also being adapted to provide flexibility to the sling body 21. The segments 26 can be at least partially hollow to assist in reducing weight of the system and improve flexibility. The pocket perimeter 24 can be closed, where the one or more segments 26 define a continuous pocket perimeter (e.g., and an isolated inner area 25) or open. More specifically, in this embodiment, the pocket perimeter 24 is closed and is defined by a single continuous segment 26. As will be described further below, the pockets 22 are shaped and designed to hold respective protective pads 20 such that the sling structure 16, combined with the protective layer 18, forms the helmet liner system 12.

[0089] In some embodiments, the sling body 21 can include sling sections 28 connected to one another and adapted to engage respective sections of the helmet shell 14. For instance, the sling sections 28 can include a front section 30, a back section 32, lateral sections 33, i.e., a left section 34 and a right section 36, and a central section 38. It is appreciated that, upon securing the helmet liner system to the helmet 10, the sling sections 28, together with the protective layer, are adapted to provide protection to a corresponding portion of the helmet 10. Particularly, the front section 30 is adapted to provide protection to a front portion of the interior of the helmet for protecting the frontal bone of the user’s head. Similarly, the back section 32 is adapted to provide protection to the back portion of the interior of the helmet, the lateral sections 33 are adapted to provide protection to the sides of the interior of the helmet and the central section 38 is adapted to provide protection to a middle portion of the interior of the helmet.

[0090] In some embodiments, the structural features of the sling body 21 can differ from one sling section 28 to another. For instance, the shape, size and / or configuration of each segment 26 forming the pockets 22 of a given sling section can be different from other segments (of other sling sections). It is also noted that segments 26 located in a common sling section can differ from each other, for example, based on their respective locations in the sling section. In yet another embodiment, the shape, size and / or configuration of a given segment 26 can be altered along its length, or that different segments can be connected together to form a pocket.

[0091] Still referring to Figures 4 to 5, in this embodiment, each pocket 22 is connected to at least one adjacent pocket 22 such that the sling sections 28 are also connected to one another. The sling body 21 can include pocket connectors 40 connected to and extending between at least two pockets 22 to enable connecting the pockets 22 together. In some embodiments, the pocket connectors 40 include a tab 42 adapted to space and connect adjacent pockets 22 from one another. In other words, adjacent pockets 22 can be spaced by a distance corresponding to a size of the tab 42. As seen in Figures 4A and5, the pockets 22 can be connected together using a pair of tabs 42 spaced from one another between adjacent pockets 22, although other configurations are possible, such as providing additional tabs 42 and / or providing one or more tabs having different shapes and / or sizes.

[0092] In this embodiment, at least some of the pocket connectors 40 define a joint 44 between corresponding pockets 22. The joints 44 provide flexibility to the sling body 21 by allowing the pockets 22 connected by a given joint 44 to at least partially fold or bend along the joint. This can be useful to enable changing the configuration of the sling structure in a three-dimensional environment, as will be further discussed below. In some embodiments, the tabs 42 can have generally the same thickness as the segments 26 of the pockets 22 to provide a suitable mix of flexibility and sturdiness to the sling structure. Alternatively, the tabs 42 can have a thickness which is smaller than the segments 26 to emphasize flexibility, or greater than the segments 26 to emphasize sturdiness.

[0093] In this embodiment, the front, back and lateral sections 30, 32, 33 can be connected to the central section 38 via connection of at least one pocket 22 (e.g., using corresponding pocket connectors 40). The joints 44 between the pockets 22 allow the sling sections 28 to go from a 2D configuration to a 3D configuration. As will be described below, the sling structure 16 can be manufactured using a 3D printing process, which is typically accomplished on a flat surface (e.g., a printing surface of a 3D printer). Therefore, the 2D configuration of the sling structure 16 can correspond to the state of sling structure following the manufacturing process. In this embodiment, the sling sections can be at least partially folded to allow the sling structure to hold a 3D configuration. It should be understood that the 3D configuration of the sling structure corresponds to the state of the sling structure configured for integration within the helmet shell. As such, it is appreciated that connecting the protective layer 18 (e.g., the protective pads 20) to the sling structure 16 can bias and / or secure the sling structure in the 3D configuration, thereby facilitating integration with the helmet.

[0094] Now referring to Figures 6 to 8, the sling structure 16 can be manufactured using digital fabrication techniques, which may include computer numerical control (CNC) and / or an additive manufacturing process, such as 3D printing, for example. The hardware used for manufacturing can be adapted to use data from a computer-aided-design (CAD) software or one or more 3D object scanners to operate and form the desired object. It should be noted that, as used herein, the expression “3D printing” refers to a manufacturing process by which an object is created by sequentially adding layers of material, whereas the expression “additive manufacturing” refers to a manufacturing process by which an object is created by sequentially adding material, which may or maynot include a layering sequence. It should also be noted that using an additive manufacturing process, such as 3D printing, allows for substantially limitless customization options, enabling the creation of various configurations which would be impossible to obtain through conventional processes like injection molding, for example.

[0095] In some embodiments, the sling structure 16 can be manufactured as a one-piece unit using a 3D printing process. The entirety of the sling structure 16, i.e., each component of the sling structure, can therefore be created generally simultaneously. More specifically, the sling structure can be created using a “single-pass 3D manufacturing process”, where each layer of the 3D layering sequence is formed from a single continuous strand of material. As such, each layer can include portions of the segments 26 defining the pockets 22 and portions of the pocket connectors 40. This manufacturing process also prevents “stop and go” motions of 3D printers, which can increase the manufacturing time of the sling structure and / or lead to mistakes and errors during the manufacturing process.

[0096] It is further noted that, once the manufacturing process is complete, the resulting sling structure 16 is a flexible and monolithic structure. It should be noted that, as used herein, the expression “monolithic structure” refers to a structure which does not include interconnected and disconnectable parts forming a whole, but rather a single, one-piece part. The monolithic structure can have different portions, although the different portions cannot be disconnected from one another as they are part of the same one-piece structure. The 3D-printing process also allows for customizable stiffness of each individual pocket 22 and / or of each individual segment 26. It is appreciated that increasing the customizability of the sling structure correspondingly provides greater control over the resulting liner system constraints at various locations. This provides a tailored approach for each helmet liner system in order to provide optimal impact absorption and wearer comfort. In alternate embodiment, the sling sections of the sling body can be manufactured independently from one another, and subsequently connected together to form the sling structure.

[0097] In some embodiments, the selection of materials for the creation of the sling structure can be important for ensuring the desired performance and durability of the helmet liner system. For instance, utilizing flexible yet resilient materials, such as thermoplastic polyurethane (TPU), can provide a suitable blend of flexibility and impact resistance. It should be noted that other materials, i.e., other than TPU, are possible and may be used for the manufacture of the sling structure.

[0098] In some embodiments, the sling structure 16 includes at least one axis of symmetry. Particularly, in this embodiment, the sling structure 16 can be separated insymmetrical left and right halves to facilitate integration within a helmet, which is similarly typically symmetrical. In some embodiments, the sling structure 16 can include a second axis of symmetry defining symmetrical front and back halves such that the sling structure can be connected to the inner surface of the helmet shell in different configurations. However, in this embodiment, the front and back section of the sling body 21 are distinct such that the sling structure is connectable to the helmet in a predetermined co nf i g u rati on / o ri e ntati o n .

[0099] Still referring to Figures 6 to 8, the sling structure 16 can be manufactured in batches or stacks. For example, a first sling structure can be manufactured using any suitable layering sequence. Then, a frangible connection 46 can be created by depositing material in strategic locations across the first sling structure which is configured to enable the launch of a second layering sequence for the creation of a second sling structure. As such, it is appreciated that the second sling structure is manufactured on top of the first sling structure, and is connected thereto via the frangible connection. Additional frangible connections and sling structures can then be created, thereby creating a stack of sling structures, as illustrated in Figures 6 to 8. The frangible connection 46 is configured to be broken to enable separation of each sling structure 16 to be used individually. In this embodiment, the frangible connection 46 is adapted to be broken manually to facilitate disconnection and separation of the sling structures 16.

[0100] In some embodiments, the frangible connection 46 can correspond to discreet frangible connectors (not shown) individually breakable to disconnect the sling structures. Alternatively, the frangible connection 46 can correspond to a partial or complete frangible layer (or layers) of material designed to enable “peeling” the sling structures from one another. In some embodiments, the configuration and / or location of the frangible connection can enable a concentration of constraints. In other words, stress can be increased in a localized zone due to a geometric difference of the part (e.g., of the frangible connector). It should be appreciated that the production costs can be lowered by implementing the stacked manufacturing process described herein, which allows for efficient utilization of materials with minimal waste.Protective pads and pad clusters

[0101] Now referring to Figures 9 to 12, the protective layer 18 of the helmet liner system 12 includes a plurality of protective pads 20 shaped and sized to engage the sling structure 16. While the protective pads 20 and corresponding protective layer 18 are described herein as being configured to cooperate with the sling structure, it should be noted that the protective pads 20 can be integrated as part of any suitable devices and / or systemsto provide protection (e.g., shock absorbance) to the device, system and / or person(s) using or operating the device or system.

[0102] Each protective pad 20 can be configured to connect with a pocket of the sling structure. More specifically, the protective pads 20 can be shaped and sized to enable connection with a single one of the pockets (or a limited few). In other words, the protective pads can connect with respective pockets such that each protective pad has a predetermined location on the sling structure. The protective pads 20 can have any suitable geometry (e.g., internal and / or external) and / or size adapted to provide protection. In this embodiment, each protective pad 20 has a customized shape and size designed according to its predetermined location across the helmet liner system and / or within the assembled helmet, for example.

[0103] In this embodiment, each protective pad 20 can include an inner section 66, an outer section 70 and an intermediate section 72. Upon connecting the helmet liner system to a helmet, the inner section 66 of the protective pads can be adapted to face the cavity of the helmet, and the outer section 70 can be adapted to engage with the helmet shell. The inner section 66 can include an engagement surface 68 configured to engage with the head of the user wearing the helmet. Therefore, it should be noted that each protective pad 10 can be designed to generally conform and cooperate with a shape of the user’s head.

[0104] In this embodiment, and with reference to Figures 10 to 12, the intermediate section 72 is illustratively defined between the inner and outer sections 66, 68. The intermediate section 72 can include tapered portions defining a groove 74 around a perimeter of the protective pad 20. Each protective pad 20 is configured to engage a pocket of the sling structure. More specifically, the segments 26 of the pockets 22 are shaped and sized to engage the groove 74 of the protective pad 20. In some embodiments, the truss-like structure of the segments 26 generally matches the shape of the groove 74 to enable and facilitate cooperation therebetween. For example, the segments 26 can have triangular cross-sectional shapes configured to facilitate pad insertion into the sling structure, while also providing adequate or strong pad retention to prevent disassembly during helmet manipulation and / or impact. As such, the protective pad 20 is at least partially secured within the closed perimeter of the pocket 22. In this embodiment, the inner and outer sections 66, 68 are wider than the groove 74, further assisting in preventing removal of the protective pads from the sling structure.

[0105] In some embodiments, the protective pads 20 can include two or more grooves 74 configured to enable connection with the sling body. It is appreciated that the pluralityof grooves enables the sling body to be coupled to the protective pads at different locations along the thickness (or the height) of the protective pad. As such, the size of the inner and outer sections can be adjusted depending on the location of the sling structure relative to the protective pads. It is also noted that the positioning of the sling structure relative to the pad height can adjust various parameters of the helmet liner system. For example, placing the sling structure closer to the user’s head can enhance comfort by increasing the size of the outer section (e.g., the section of the pad between the sling structure and the helmet shell), while placing the sling structure closer to the shell can increase structural support. Moreover, the plurality of grooves 74 along the protective pads can also allow for a plurality of sling structures to be coupled thereto. As such, multiple sling structures can overlap one or more pad clusters which can provide increased flexibility in distributing support and enhancing stability across the helmet liner system.

[0106] The protective pads can be manufactured using digital fabrication techniques, similar to the sling structure previously described. For example, the protective pads can be manufactured using an additive manufacturing process, such as 3D printing. International patent application publication No. WO2023279210A1 describes protective pads for use in a helmet liner system, and further described possible manufacturing methods of such pads. The manufacturing methods, including the layering sequences described therein, can also be applied to the manufacture of the protective pads of the present disclosure. As such, the teachings of WO2023279210A1 are incorporated herein by reference.

[0107] In some embodiments, the protective pads 20 are manufactured using relatively resilient material such that forces applied thereto can deform the protective pad as it absorbs at least a portion of those forces to provide protection to the device, the system and / or the person(s) using or operating the device or system. Of note, the deformation of the protective pads is generally reversible. For example, the protective pad may be in a “deformed” or “compressed” configuration when a force is applied to the protective pad or when energy is absorbed by the protective pad, and the protective pad may be in a “relaxed” or “original” configuration when no force is applied to the protective pad or after the energy is released from the protective pad. It should also be noted that the protective pad described herein can be configured for single impact applications, where the pads deform permanently (e.g., plastic deformation) to absorb the forces / energy.

[0108] It should be noted that, materials designed for impact absorption, such as TPU foam or specialized polymer blends, can be used for the manufacture of the protective pads and corresponding pad clusters. It is also noted that the sling structure and the padclusters can be made of the same material (e.g., TPU), which can facilitate manufacturing and is also interesting for recycling purposes.

[0109] In some embodiments, the protective layer 18 can have pad clusters 50, each including a plurality of protective pads 20 cooperating within one another and adapted to engage a common section of the sling structure. For example, the protective layer can include a front cluster 52 engageable with the front section of the sling structure. In a similar fashion, the protective layer can include a back cluster 54, lateral clusters 56, i.e. , a left cluster 57 and a right cluster 58, and a central cluster 60 engageable with the back section, the lateral sections and the central section of the sling structure, respectively. It is appreciated that, upon securing the helmet liner system to the helmet 10, the protective pads, which are connected to the sling structure at predetermined locations, can be adapted provide protection to corresponding predetermined portions of the helmet 10. In some embodiments, the protective pads 20 of a given pad cluster 50 can have a different thickness than the protective pads of a different pad cluster, for example, due to its location within the helmet 10, among other possible factors. It should also be noted that protective pads within a common pad cluster 50 can similarly have different thicknesses, shapes, sizes, configurations, etc.

[0110] In some embodiments, each protective pad 20 of a given pad cluster 50 is connected to at least one adjacent protective pad 20. Therefore, each pad of said pad cluster 50 can be manipulated together as a single unit. The pad clusters can include pad connectors 62 connected to and extending between at least two protective pads 20. In some embodiments, the pad connectors 62 are adapted to space and connect adjacent protective pads 20 to one another. In other words, adjacent protective pads 20 can be spaced by a distance corresponding to a size of the pad connector 62. As seen in Figures 9 and 9A, the protective pads 20 can be connected together using one, two or three pad connectors spaced from one another between adjacent protective pads 20, although other configurations are possible, such as providing additional pad connectors 62 and / or pad connectors having different shapes and / or sizes.

[0111] In this embodiment, at least some of the pad connectors 62 define a junction 64 between corresponding protective pads 20. The junctions 64 can be adapted to provide flexibility to the pad cluster 50 by allowing the protective pads 20 connected to a given junction 64 to at least partially fold or bend along the junction (e.g., along the connection defined by the pad connectors 62). This can be useful to enable changing the configuration of the pad cluster 50 from a two-dimensional configuration to a three-dimensional configuration, as will be further discussed below. In some embodiments, the pad connectors 62 can have generally the same thickness as the protective pads 20themselves to provide a suitable mix of flexibility and sturdiness to the pad cluster 50, and therefore to the protective layer 18. Alternatively, the pad connectors can have a thickness which is smaller than the protective pads 20 to emphasize flexibility, or greater than the protective pads 20 to emphasize sturdiness.

[0112] In some embodiments, each pad cluster 50 can be manufactured as a one-piece unit using 3D-printing techniques. The entirety of the pad clusters 50, e.g., the protective pads and the pad connectors, can be created generally simultaneously. In this embodiment, the pad cluster 50 can be created using a “single-pass 3D manufacturing process”, where each layer of the 3D layering sequence is formed from a single continuous strand of material (e.g., similar to the manufacturing process of the sling structure). It is further noted that, once the manufacturing process is complete, the resulting pad cluster 50 is a flexible and monolithic structure. In alternate embodiments, the protective pads can be manufactured independently from one another, and subsequently connected together to form the pad clusters.

[0113] In some embodiments, at least some of the pad clusters 50 can include at least one axis of symmetry to enable connection with the sling structure (which can similarly include corresponding axes of symmetry). In this embodiment, the lateral clusters do not have respective axes of symmetry. However, upon connection with respective sections of the sling body, the lateral clusters can be symmetrical relative to each other.

[0114] Referring back to Figure 3, in some embodiments, the helmet liner system 12 can include cheek pads 27 configured to be integrated within the helmet to provide protection to corresponding sections of the helmet (e.g., along the sides of the helmet). The cheek pads 27 can be standalone pieces or integrated with the rest of the liner system 12. As such, it is appreciated that the cheek pads 27 can be 3D-printed pieces, similar to the pad clusters and / or sling structure previously described. This configuration provides an extra layer of customization to the helmet liner system, where the cheek pads can be 3D-printed and custom-made for a specific helmet model and / or based on user specifications, for example.Helmet liner assembly

[0115] As seen in Figures 2, 3, 10 and 11 , the pad clusters 50 are configured to engage and connect with respective sections of the sling body 21. As described herein, both the sling structure and the protective layer can be made via a 3D-printing process and / or in a generally 2D configuration. In other words, the sling body 21 and the pad clusters 50 are adapted to lay generally flat on a surface prior to being assembled to form the helmet linersystem. The assembly process biases the sling structure and the pad clusters into a 3D configuration configured to be integrated in the helmet shell.

[0116] In this embodiment, the protective pads 20 of each pad cluster 50 are configured to engage the pockets of the corresponding section of the sling body. As seen in Figure 10, at least some of the protective pads 20 can engage respective pockets while maintaining the sling structure in the 2D configuration (e.g., flat on a surface). In this embodiment, the sling sections 28 can include one or more connecting pockets 80 configured to cooperate with one of the protective pads 20 of a different pad cluster 50. It should thus be noted that, once the pad clusters 50 are coupled to respective sling sections 28, one or more protective pads 20 can remain disconnected (e.g., not coupled to a pocket 22 of the sling body). The sling structure and / or the pad clusters are adapted to be at least partially bent along the joints 44 and junctions 64 to enable the disconnected protective pads to engage respective connecting pockets 80. Once engaged, the assembled sling structure and pad clusters cooperate to maintain the bent configuration.

[0117] It is thus noted that, once each connecting pocket 80 is coupled to a corresponding one of the protective pads, the sling structure and the pad clusters are configured in the 3D configuration, and the helmet liner system 12 is assembled, as shown in Figures 2, 3 and 11. The helmet liner system is thus configured to retain its 3D shape autonomously. As such, the need for external supports can be eliminated.

[0118] In the exemplary embodiment of Figure 10, the front sling section includes a first connecting pocket 80a provided on a first side, and a second connecting pocket 80b provided on a second side. Each connecting pocket 80a, 80b of the front sling section 30 is configured to receive and connect with one of the protective pads of respective lateral clusters 56, thereby joining the front section with the lateral sections. Similarly, the lateral sections each include a pair of connecting pockets 80 for cooperation with a protective pad of the central cluster 60 and a protective pad of the back cluster 54, thereby joining the lateral sections with the central and back sections of the sling body. It is noted that, coupling each connecting pocket 80 with a corresponding one of the protective pads 20, the helmet liner system is assembled and configured to hold its shape.

[0119] It should be noted that the sling body can include any suitable number of connecting pockets 80, located at any suitable location (e.g., coupled to any suitable sling section). It is thus appreciated that the pad clusters can correspondingly include any suitable number of disconnected pads configured to engage with respective connecting pockets for configuring the helmet liner system in the 3D configuration.

[0120] From the above, it is appreciated that the helmet liner system is formed via the assembly of the protective layer (e.g., the pad clusters) with the sling structure. While both of these components are manufactured on flat surfaces and in a generally 2D (e.g., flat) configuration, the assembly of these components urges one or both of them into a 3D configuration. More specifically, the sling structure and pad clusters interact generally seamlessly to create a cohesive 3D shape when assembled. The flexible material used for the manufacture of at least one of the sling structure and the pad clusters allows for relative movements between the sling structure and the protective pads (e.g., during impacts), which can enhance the helmet liner's effectiveness.

[0121] Now referring to Figures 13 to 21 , the helmet liner system 12 can include liner anchors 90 configured to enable connection between the helmet liner system 12 and the helmet 10. In some embodiments, the liner anchors 90 can be integrated with the helmet shell 14 and configured to enable connection and disconnection of the assembled sling structure and pad clusters. Alternatively, the liner anchors 90 can be connectable to at least one of the sling structure and pad clusters, and configured to be removably connectable to the helmet shell 14.

[0122] In this embodiment, the liner anchors 90 include at least a front anchor 92 and a back anchor 94 respectively connectable to the front and back portions of the helmet. Each liner anchor 90 can include a helmet connector 96 connectable to the helmet shell 14 and a liner connector 98 connectable to at least one of the sling structure and the protective layer (e.g., one of the protective pads or pad clusters). The helmet connector 96 can include an anchor plate 100 provided with one or more fastener openings 102 enabling connection with the helmet shell via a corresponding fastener 103. The fastener 103 can be part of the standard hardware of the helmet assembly such that no additional fasteners are required to connect the helmet liner system to the helmet. However, it is appreciated that, in other embodiments, the helmet liner system can require its own fasteners, distinct of any existing fasteners of the helmet.

[0123] In this embodiment, the liner connector 98 can include an anchor pocket 104 configured to engage with at least one protective pad 20. The anchor pocket 104 can be defined by segments similar to those defining the pockets 22 of the sling body 21. The segments of the anchor pocket 104 can therefore be adapted to engage the groove 74 (or one of the grooves) of the protective pads. In some embodiments, the segments of the anchor pocket 104 are adapted to share the groove 74 of the protective pad which is engaged by the sling structure. For example, the segments can be positioned side by side within the groove, or can overlap one another, among other possibilities. Alternatively, the segments of the anchor pocket 104 can engage a different groove 74 than the oneengaged by the sling structure. In yet another embodiment, the pad clusters can include an additional protective pad not associated (e.g., not coupled) to any of the pockets of the sling body. Instead, the additional protective pad can be configured to be coupled to the anchor pocket 104 to enable connection of the helmet liner system to the helmet. It should therefore be noted that the liner anchors 90 are removably connectable to the helmet liner system 12 (e.g., to the protective layer) and configured to be secured to the helmet shell 14, thus connecting the helmet liner system 12 to the helmet 10.

[0124] The liner anchors 90 can be manufactured using similar techniques as those described above in relation with the sling structure and / or the pad clusters. Particularly, the liner anchors 90 can be 3D printed, although other manufacturing processes are possible and may be used. It should also be noted that other configurations of the liner anchor 90 are possible. For example, the anchor pocket 104 can be manufactured together with the sling structure. Therefore, the helmet connector 96 can be integrated as part of the one-piece unit corresponding to the sling body. Alternatively, the liner anchor 90 can be manufactured together with one of the protective pads of a pad cluster. As such, upon connecting the pad cluster with the sling structure, the helmet connector 96 is correspondingly connected to the sling structure for enabling connection of the assembled liner system to the helmet.

[0125] The liner anchors 90 can be made of any suitable material and have any suitable dimensions providing a suitable flexibility, strength and / or rigidity to provide a secure connection between the helmet liner system and the helmet. As seen in Figures 18 and 20, the anchor plates of the liner anchors 90 can be configured to be folded onto itself to enable connection with the helmet shell 14 (see Figures 19 and 21). In some embodiments, the liner anchors 90 can include junctures between the helmet connector 96 and the liner connector 98, thus enabling the helmet connector 96 (e.g., the anchor plate) to be bent along the juncture to enable and facilitate connection with the helmet shell.

[0126] It will be appreciated from the foregoing disclosure that there is provided a versatile and effective helmet liner system configured to improve protection and comfort for the wearer. The solution involves the integration of a 3D printed sling structure with multiple pad clusters to form a comprehensive helmet liner system. The sling structure serves as the backbone of the liner system and features specific shapes and truss-like structures designed to accommodate and provide structural support for the pad clusters. The protective layer has impact absorption pads which are 3D printed in clusters or groups, where each pad is designed to fit into respective pockets of the sling structure. The pad clusters are strategically positioned to ensure improved coverage and protection.The sling structure and pad clusters interact seamlessly to create a cohesive 3D shape when assembled. The flexible material used for the manufacture of the sling structure and / or the pad clusters allows for movements of the pads during impact, thus enhancing the liner's effectiveness. The assembled liner is configured to be integrated with the helmet shell, providing an advanced protective system. The sling structure is designed to also allow for easy integration with other helmet components through one or more anchor points. Additional sling pieces and / or parts can be added as connectors to link the sling backbone to the shell.

[0127] The sling structure includes segments having truss-like configurations with hollow spaces in order to maintain lightness and flexibility without compromising structural integrity. The truss-like segments can be designed to allow different stiffness in various directions (e.g., extension vs. flexion), enhancing the adaptability and effectiveness of the liner. The shape and arrangement of the pad clusters can also be adjusted and honed to conform within the sling pockets to improve conformability, thus improving impact absorption and overall comfort.

[0128] The assembly process of the helmet liner system described herein is intuitive and efficient. The design of the truss-like segments of the sling (e.g., a male component) and the recesses of the pads (e.g., a female component) enable a straightforward assembly process. For example, a truss shape in a triangle configuration allows for easy pad insertion into the sling, while also providing strong retention to prevent accidental / undesired disassembly. The assembly process can resemble a simple puzzle, ensuring straightforward integration. It should also be noted that a unique sling design can accommodate different helmet liner sizes (e.g., S, M, L, XL, XXL) by adjusting the position of the recesses in pads of varying heights.

[0129] The helmet liner system design facilitates and streamlines integration with the helmet shell, requiring only a few anchor points for attachment of the full liner within the helmet. The sling structure functions as a suspended net within the shell, providing the required support for the protective layer while reducing interference with the helmet's overall structure.

[0130] Computer-aided design (CAD) software can be used to assist in the development process, allowing for accurate modeling of the sling structure and pad clusters. Additionally, finite element analysis (FEA) software can also be used in simulating and improving the system's performance under various impact scenarios, ensuring desired efficacy and safety rating, for example.

[0131] Additive manufacturing (e.g., 3D printing) technology stands out as an effective method for manufacturing the sling structure and pad clusters. This approach allows for increased customization, enabling the creation of intricate configurations that are generally unattainable through conventional processes such as injection molding, for example. Moreover, the selection of materials is important in ensuring the performance and durability of the system. Utilizing flexible yet resilient materials such as thermoplastic polyurethane (TPU) for the sling structure provides a balance of flexibility and impact resistance. Similarly, materials designed for impact absorption, like TPU foam or specialized polymer blends, are similarly well suited for the manufacture of the pad clusters.

[0132] The present disclosure may be embodied in other specific forms without departing from the subject matter of the claims. The described example embodiments are to be considered in all respects as being only illustrative and not restrictive. For example, and with reference to Figures 22 to 25, the segmentation of the liner system 12 can vary, offering alternatives like a Voronoi split 110 and / or round pads 112. Various shapes, including circumferential shapes, can be explored for designing the sling pockets 22, allowing for customization based on specific user preferences and requirements. Similarly, different designs for the segments or pocket connectors between the sling pockets can be implemented to enable a corresponding range of motions between the pads. This customization allows for tailored solutions that accommodate different levels of impact absorption and wearer mobility.

[0133] While the above-described helmet liner system is described in relation with a helmet, such as a football helmet, it is appreciated that the technology can be implemented in different gear and / or different fields. For instance, the liner system could be adapted to create protective liners for sports equipment such as back protectors, knee pads, elbow pads, and shin guards. Military helmets and body armor could similarly benefit from the advanced protection offered by the liner system. Workers in industries such as construction, manufacturing, and mining often require protective headgear. It is thus noted that the liner system can be implemented to enhance the safety and comfort of hard hats and other industrial safety gear. In some instances, the flexibility and impact-absorbing properties of the liner system can make it suitable for medical applications. It could be utilized in orthopedic braces, prosthetic devices, or even as padding for medical beds and wheelchairs to improve patient comfort and safety. Car manufacturers could integrate the technology into vehicle components such as seat cushions and headrests, among many other possible applications.

[0134] The described example implementations are to be considered in all respects as being only illustrative and not restrictive. In the present disclosure, an embodiment is an example or implementation of the described devices, systems and methods. The various appearances of “one embodiment,” “an embodiment” or “some embodiments” do not necessarily all refer to the same embodiments. Although various features may be described in the context of a single embodiment, the features may also be provided separately or in any suitable combination. Conversely, although the described devices, systems and methods may be described herein in the context of separate embodiments for clarity, it may also be embodied in a single embodiment. Reference in the specification to “some embodiments”, “an embodiment”, “one embodiment”, or “other embodiments”, means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least some embodiments, but not necessarily in all embodiments.

[0135] As used herein, the terms “coupled”, “coupling”, “attached”, ’’connected” or variants thereof as used herein can have several different meanings depending in the context in which these terms are used. For example, the terms coupled, coupling, connected or attached can have a mechanical connotation. For example, as used herein, the terms coupled, coupling or attached can indicate that two elements or devices are directly connected to one another or connected to one another through one or more intermediate elements or devices via a mechanical element depending on the particular context.

[0136] Similarly, positional descriptions such as “top”, “bottom”, “above”, “under”, “below”, “left”, “right”, “front”, “rear”, “parallel”, “perpendicular”, “transverse”, “inner”, “outer”, “internal”, “external”, and the like should, unless otherwise indicated, be taken in the context of the figures and should not be considered limiting.

[0137] In the above description, the same numerical references refer to similar elements. Furthermore, for the sake of simplicity and clarity, namely so as to not unduly burden the figures with several references numbers, not all figures contain references to all the components and features, and references to some components and features may be found in only one figure, and components and features of the present disclosure which are illustrated in other figures can be easily inferred therefrom. The implementations, geometrical configurations, materials mentioned and / or dimensions shown in the figures are optional, and are given for exemplification purposes only.

[0138] In addition, although the optional configurations as illustrated in the accompanying drawings comprises various components and although the optionalconfigurations of the described devices and systems as shown may consist of certain geometrical configurations as explained and illustrated herein, not all of these components and geometries are essential and thus should not be taken in their restrictive sense, i.e. should not be taken as to limit the scope of the present disclosure. It is to be understood that other suitable components and cooperations thereinbetween, as well as other suitable geometrical configurations may be used for the implementation and use of the described devices and systems, and corresponding parts, as briefly explained and as can be easily inferred herefrom, without departing from the scope of the disclosure.

Claims

CLAIMS1 . A helmet liner system for integration within a helmet, comprising : a flexible sling structure defining a plurality of pockets, the flexible string structure being configurable between a two-dimensional configuration, where the flexible string structure is adapted to lay substantially flat, and a three-dimensional configuration, where the flexible string structure is adapted to be integrated into a helmet shell; a protective layer including a plurality of pads, each pad being shaped and sized to engage respective pockets of the sling structure, wherein the flexible sling structure is biased from the two-dimensional configuration to the three-dimensional configuration upon engagement of the plurality of pads with the plurality of pockets.

2. The helmet liner system of claim 1 , wherein each one of the plurality of pockets includes one or more segments defining a perimeter, and wherein the plurality of pads are each shaped and sized to engage respective pockets within the perimeter.

3. The helmet liner system of claim 2, wherein the perimeter of at least some of the pockets is a closed perimeter.

4. The helmet liner system of claim 2 or 3, wherein each pocket of the flexible sling structure is connected to at least one adjacent pocket via one or more pocket connectors.

5. The helmet liner system of claim 4, wherein the pocket connectors extend between and connect adjacent pockets to one another such that the adjacent pockets are spaced from each other by a distance corresponding to a length of the pocket connectors.

6. The helmet liner system of claim 4 or 5, wherein the pocket connectors define joints between adjacent pockets enabling relative movement between the pockets.

7. The helmet liner system of any one of claims 4 to 6, wherein the pocket connectors and / or the segments of the pockets are at least partially hollow.

8. The helmet liner system of any one of claims 1 to 7, wherein the flexible string structure includes a central section, a front section, a back section, a left section and a right section, wherein each section of the flexible string structure includes several pockets.

9. The helmet liner system of claim 8, wherein at least one pocket of the front section is connected to the central section.

10. The helmet liner system of claim 8 or 9, wherein at least one pocket of the back section is connected to the central section.

11. The helmet liner system of any one of claims 8 to 10, wherein at least one pocket of the left section and the right section is connected to the central section.

12. The helmet liner system of any one of claims 8 to 11 , wherein the left section is symmetrical with the right section.

13. The helmet liner system of any one of claims 8 to 12, wherein each of the front, back, left and rights sections are movable relative to the central section.

14. The helmet liner system of claim 13, wherein each of the front, back, left and rights sections are pivotally movable relative to the central section along respective joints.

15. The helmet liner system of any one of claims 8 to 14, wherein the segments of the pockets in different sections of the flexible string structure have respective shapes, sizes and / or configurations.

16. The helmet liner system of any one of claims 8 to 15, wherein the segments of the pockets in each section of the flexible string structure have generally the same shape, size and / or configurations.

17. The helmet liner system of any one of claims 1 to 16, wherein the flexible string structure is a one-piece unit.

18. The helmet liner system of any one of claims 1 to 17, wherein the flexible string structure is a 3D-printed structure.

19. The helmet liner system any one of claims 8 to 18, wherein the plurality of pads of the protective layer includes a plurality of pad clusters connectable to respective sections of the flexible sling structure.

20. The helmet liner system of claim 19, wherein each pad of a common pad cluster is connected to at least one adjacent pad via one or more pad connectors.

21. The helmet liner system of claim 20, wherein the pad connectors extend between and connect adjacent pads to one another such that the adjacent pads are spaced from each other by a distance corresponding to a length of the pad connectors.

22. The helmet liner system of claim 20 or 21 , wherein the pad connectors define junctions between adjacent pads enabling relative movement between the pads.

23. The helmet liner system of any one of claims 20 to 22, wherein the pad connectors and / or the pads are at least partially hollow.

24. The helmet liner system of any one of claims 19 to 23, wherein each pad cluster is a one-piece unit.

25. The helmet liner system of any one of claims 19 to 24, wherein each pad cluster is a 3D-printed structure.

26. The helmet liner system of any one of claims 19 to 25, wherein each pad of the protective layer includes a groove defined about a perimeter thereof shaped and sized to receive the segments of a given pocket of the flexible string structure.

27. The helmet liner system of claim 26, wherein the segments of the pockets and the groove of the pads are configured to cooperate to prevent disconnection between the flexible string structure and the protective layer.

28. The helmet liner system of claim 26 or 27, wherein the segments and the grooves have complementary shapes configured to prevent disconnection therebetween.

29. The helmet liner system of claim 28, wherein the segments have a triangular cross- sectional shape.

30. The helmet liner system of any one of claims 26 to 29, wherein the groove is a first groove, and wherein one or more pads of the protective layer includes a second groove configured to cooperate with a second flexible string structure.

31. The helmet liner system of claim 30, wherein the second groove is adjacent the first groove.

32. The helmet liner system of any one of claims 26 to 31 , wherein each pad includes an inner section extending a first side of the groove and an outer section extending on a second side of the groove opposite the inner section, and wherein, upon integration of the helmet liner system in the helmet, the inner section is positioned adjacent a head of a user, and the outer section is positioned adjacent to an inner surface of the helmet.

33. The helmet liner system of any one of claims 19 to 32, wherein the pad clusters include a front cluster, a back cluster, a central cluster, a left cluster and a right cluster engageable with the front section, the back section, the central section, the left section and the right section of the flexible string structure, respectively, and wherein at least one section of the flexible string structure includes a connecting pocket configured to engagethe pad of an adjacent pad cluster, thereby biasing the flexible string structure towards the three-dimensional configuration.

34. The helmet liner system of any one of claims 1 to 33, further comprising one or more liner anchors configured to enable connection between the assembled flexible string structure and protective layer and the helmet.

35. The helmet liner system of claim 34, wherein each liner anchor includes a liner connector connectable to at least one of the sling structure and the protective layer and a helmet connector connectable to the helmet.

36. The helmet liner system of claim 35, wherein the liner connector includes anchor segments defining an anchor pocket configured to engage at least one of the pads of the protective layer.

37. The helmet liner system of claim 36, wherein the anchor segments have generally the same shape, size and / or configuration as the segments of the pockets of the flexible string structure.

38. The helmet liner system of any one of claims 35 to 37, wherein the liner connector is manufactured together with the flexible string structure.

39. The helmet liner system of any one of claims 35 to 37, wherein the liner connector is removably connectable to the protective layer.

40. The helmet liner system of any one of claims 35 to 39, wherein the helmet connector includes an anchor plate configured to engage an inner surface of the helmet, the anchor plate being configured to be connected to the helmet via one or more mechanical fasteners.

41. The helmet liner system of claim 40, wherein the one or more mechanical fasteners correspond to standard helmet hardware.

42. A helmet liner system, comprising : a sling structure having a sling body defining a plurality of pockets, each pocket being connected to at least one adjacent pocket via at least one connector, wherein the sling body is 3D-printed according to a 3D-printing protocol such that each pocket and each connector are created together as part of the 3D-printing protocol and form a continuous one-piece unit;a protective layer including a plurality of pads, each pad being shaped and sized to engage respective pockets of the sling structure.

43. A helmet liner system, comprising : a sling structure having a sling body with a plurality of pockets connected to one another, each pocket comprising one or more segments defining a pocket perimeter, each pocket being connected to at least one other pocket via at least one connector extending between respective segments; a protective layer including a plurality of pad clusters made up of a plurality of pads connected to one another, each pad being adapted to engage respective pockets of the sling structure such that each pad cluster is adapted to cover respective sections of the sling structure.

44. A helmet liner system, comprising : a sling structure having a sling body having sling sections including a front section, a back section, a right section and a left section, each sling section of the sling body having a plurality of pockets connected to one another; a protective layer including pad clusters made up of a plurality of pads connected to one another, the pad clusters are connectable to respective sling sections, wherein at least one pad of a given pad cluster is connectable to a different sling section to bias the sling body in a shellshaped configuration for integration in a helmet shell.

45. A helmet comprising a helmet shell defining an inner volume shaped and sized for the integration of the helmet liner system as defined in any one of the preceding claims.

46. A sling structure for supporting protective pads of a helmet liner system, the sling structure comprising : a sling body defining a plurality of pockets configured to hold respective protective pads, each pocket being connected to at least one adjacent pocket via at least one connector, wherein the sling body is 3D-printed according to a 3D-printing protocol, and wherein each pocket and corresponding connector are created together as part of the 3D-printing protocol and form a continuous one-piece unit.

47. A sling structure for supporting protective pads of a helmet liner system, the sling structure comprising : a flexible sling body defining a plurality of pockets configured to hold respective protective pads, the flexible body being configurable from a two-dimensional configuration, where the flexible body is adapted to lay substantially flat, to a three-dimensional configuration, where the flexible string structure is adapted to be integrated into a helmet shell, upon engagement of the protective pads within respective pockets of the flexible sling body.

48. A method of manufacturing a helmet liner system, comprising :3D-printing a sling structure having a plurality of pockets connected to one another via at least one connector;3D-printing a plurality of protective pads adapted to collectively form a protective layer; assembling the protective layer and the sling structure by engaging the plurality of protective pads in respective pockets to form the helmet liner system, wherein assembling the protective layer and the sling structure flexes the sling structure in a predetermined configuration to facilitate integration of the helmet liner system in a helmet shell.

49. A method of manufacturing a helmet liner system, comprising :3D-printing a sling structure having a plurality of pockets spaced from one another and connected to at least one other pocket via at least one connector by stacking a plurality of layers on each other, wherein each layer is formed of a single continuous string of material such that every pocket of the sling structure is formed simultaneously;3D-printing a plurality of protective pads adapted to collectively form a protective layer; assembling the protective layer and the sling structure by engaging the plurality of protective pads in respective pockets to form the helmet liner system.

50. A method of manufacturing a sling structure for supporting protective pads of a helmet liner system, the method comprising :3D-printing a sling body by stacking a plurality of layers of material on each other, the sling body having a plurality of pockets spaced from one another and connected to at least one other pocket via at least one connector, wherein each layer of material is formed of a single continuous string of material such that the plurality of pockets and each connector is formed together as a one-piece unit.

51. The method of claim 50, further comprising :3D-printing a frangible connection on top of the sling body; and3D-printing a second sling body on top of the frangible connection.

52. The method of claim 51 , wherein a plurality of sling structures are manufactured in a stack of alternating sling bodies and frangible connections.

53. The method of claim 51 or 52, wherein the sling bodies are adapted to be disconnected from one another by breaking the frangible connection.

54. The method of claim 53, wherein the frangible connection is breakable manually.

55. The method of claim 53 or 54, wherein breaking the frangible connection includes peeling adjacent sling bodies from one another along the frangible connection.

56. The method of any one of claims 51 to 55, wherein the frangible connection comprises one or more layers of material provided at discreet locations on the previous sling body.

57. The method of claim 53, wherein the frangible connection comprises one or more layers of material provided along an entire surface area of the previous sling body.

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