Helmet Impact Liner

Abstract

A helmet impact liner includes a shell liner that couple the helmet impact liner to a helmet shell. The shell liner includes an inner surface and an outer surface and a channel extending along the outer surface. A first impact attenuation pad is detachably coupled to the shell liner and positioned within the channel at the outer surface of the shell liner.

Description

Docket No. 063758-02-5178-WOTITLE

[0001] Helmet Impact LinerCROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application No.63 / 746,656 filed January 17, 2025 entitled “Helmet Impact Liner”, which is incorporated by reference herein in its entirety.TECHNICAL FIELD

[0003] The present disclosure generally relates to helmet impact liners and, in some embodiments, to helmet impact liners with a detachable impact attenuation pad.SUMMARY

[0004] In one embodiment there is a helmet impact liner including a shell liner configured to couple the helmet impact liner to a helmet shell, the shell liner including an inner surface and an outer surface and a channel extending along the outer surface, and a first impact attenuation pad detachably coupled to the shell liner and positioned within the channel at the outer surface of the shell liner

[0005] In some embodiments, the shell liner includes a nape cover extending downwardly from a rear portion of the shell liner, and the helmet impact liner further includes an adjustment assembly coupled to the nape cover and configured to adjust a position of the nape cover relative to a front portion of the shell liner. In some embodiments, the adjustment assembly includes a nape plate detachably coupled to the nape cover, a knob rotatably coupled to the nape plate, and a cable fixedly coupled to the knob at one terminal end and fixedly coupled to the shell liner at the opposite terminal end. In some embodiments, the opposite terminal end of the cable is fixedly coupled to the shell liner via an anchor fixedly coupled to the shell liner proximate the front portion thereof.

[0006] In some embodiments, the nape plate is attachable to the nape cover in a plurality of different positions. In some embodiments, the nape plate is detachably coupled to the nape cover via a hook and loop fastener. In some embodiments, the nape cover is integrally formed with the shell liner. In some embodiments, the helmet impact liner further includes a second impact attenuation pad coupled to the shell liner and positioned at least partially between the inner surface and outer surface thereof. In some embodiments, the second impact attenuation pad is detachably coupled to the shell liner.

[0007] In some embodiments, the shell liner defines an aperture through which the second impact attenuation pad extends. In some embodiments, a portion of the second impact attenuation pad protrudes from the outer surface of the shell liner. In some embodiments, the second impact attenuation pad does not extend beyond the inner surface of the shell liner. In some embodiments, the second impact attenuation pad is fixedly coupled to the shell liner. In some embodiments, the shell liner defines a chamber between the outer surface and inner surface thereof and the second impact attenuation pad is entirely enclosed within the chamber.

[0008] In some embodiments, the helmet impact liner further includes a plurality of second impact attenuation pads each coupled to the shell liner and positioned at least partially between the inner surface and outer surface of the shell liner. In some embodiments, the helmet impact liner further includes a comfort pad detachably coupled to the inner surface of the shell liner. In some embodiments, the comfort pad includes a tab that wraps around a peripheral edge of the shell liner. In some embodiments, the channel extends along a crown of the shell liner at the outer surface. In some embodiments, the channel extends between opposed side surfaces of the shell liner and along the crown thereof. In some embodiments, the first impact attenuation pad is entirely exterior to the shell liner. In some embodiments, the shell liner is comprised of a fabric material. In some embodiments, the shell liner is comprised of a foam material.

[0009] In another embodiment there is a helmet impact liner including a shell liner configured to couple the helmet impact liner to a helmet shell, the shell liner including an inner surface, an outer surface and a nape cover extending downwardly from a rear portion of the shell liner, an adjustment assembly coupled to the nape cover and configured to adjust a position of the nape cover relative to a front portion of the shell liner, a first impact attenuation pad detachably coupled to the shell liner at the outer surface thereof, a second impact attenuation pad coupled to the shell liner and positioned at least partially between the shell liner between the inner surface and outer surface thereof, and a comfort pad detachably coupled to the inner surface of the shell liner.

[0010] In another embodiment there is a method of mounting a communication headset to a helmet impact liner, the method including positioning a shell liner of a helmet impact liner on a user’s head, positioning a headband of a communication headset within a channel extending along an outer surface of the shell liner, and positioning a first impact attenuation pad above the headband and within the channel such that the headband is sandwiched between the shell liner and first impact attenuation pad. In some embodiments, the channel extends between opposed side surfaces of the shell liner and along a crown thereof.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The following detailed description of embodiments of the helmet impact liner, will be better understood when read in conjunction with the appended drawings of exemplary embodiments. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.

[0012] In the drawings:

[0013] Fig. l is a perspective view of a helmet impact liner in accordance with an exemplary embodiment of the present disclosure;

[0014] Fig. 2 is a side elevational view of the helmet impact liner of Fig. 1;

[0015] Fig. 3 is a side elevational view of a shell liner of the helmet impact liner of Fig. 1;

[0016] Fig. 4 is a perspective view of the helmet impact liner of Fig. 1 with a communications headset mounted thereto;

[0017] Fig. 5 is a flowchart illustrating a method of mounting a communication headset to a helmet impact liner in accordance with an exemplary embodiment of the present disclosure;

[0018] Fig. 6 is a rear perspective view of the helmet impact liner of Fig. 1;

[0019] Fig. 7 is a rear perspective view of an adjustment assembly in accordance with an exemplary embodiment of the present disclosure;

[0020] Fig. 8 is a side elevational view illustrating the adjustment assembly of Fig. 7 coupled to the shell liner of Fig. 1;

[0021] Fig. 9 is a side elevational view illustrating the shell liner of Fig. 1 and adjustment assembly of Fig. 7 fit to a wearer’s head;

[0022] Fig. 10 is a sectional view of the helmet impact liner of Fig. 1;

[0023] Fig. 11 is a side elevational view of a comfort padding of the helmet impact liner of Fig.1;

[0024] Fig. 12 is a front perspective view of a helmet impact liner in accordance with another exemplary embodiment of the present disclosure;

[0025] Fig. 13 is a rear perspective view of the helmet impact liner of Fig. 12;

[0026] Fig. 14 is a side elevational view of the helmet impact liner of Fig. 12; and

[0027] Fig. 15 is a side cross-sectional view of the helmet impact liner of Fig. 12.DETAILED DESCRIPTION

[0028] Helmets for head protection are worn in a variety of environments and for various purposes. The primary purpose of a helmet is to mitigate the effects of impact on the user’s head. Helmets are meticulously designed to absorb and dissipate the force generated by ballistic threats, explosions, or other high-velocity projectiles. Helmets used in military applications are designed to provide comprehensive protection against various threats, including ballistic, blunt, and blast impacts. The incorporation of advanced materials, such as aramid fibers or ceramic plates, enhances the helmet’s ability to withstand and disperse the impact energy, reducing the risk of traumatic head injuries in the field. Moreover, these helmets often feature elements that address specific military needs, such as compatibility with communication systems, night vision devices, and camouflage.

[0029] In helmet design, the integration of effective impact attenuation and interior padding is essential to provide comprehensive protection against a wide range of threats. The combination of advanced materials, innovative design, and a focus on user comfort ensures that military helmets meet the stringent requirements of modem warfare while prioritizing the safety and well-being of the wearer.

[0030] Referring to the drawings in detail, wherein like reference numerals indicate like elements throughout, there is shown in Figs. 1-4 and 6-11 a helmet impact liner, generally designated 100, in accordance with an exemplary embodiment of the present disclosure. In some embodiments, the helmet impact liner 100 is configured to enable a communications headband to be attached thereto. In some embodiments, the helmet impact liner 100 is configured to detachably couple one or more impact pads thereto. In some embodiments, the helmet impact liner 100 is configured to enable a user to adjust the fit of the liner to their head. In some embodiments, the helmet impact liner 100 is configured to enable a user to tension the liner 100 onto their head. In some embodiments, the impact liner 100 of the present disclosure is configured to include a repositionable adjustment assembly configured to tension the liner 100.

[0031] Referring to Figs. 1-2, there is shown a helmet impact liner 100 configured to be coupled to a helmet 10. In some embodiments, the helmet impact liner 100 is configured to be attached to the interior surface of a helmet 10 such that it is positioned between the helmet 10 and a wearer’s head 12. In Figs. 1-2 the outline of a helmet 10 is shown and in the figures the helmet 10 is illustrated as being transparent so as not to obscure the helmet impact liner 100. The helmet 10 may be a helmet shell for use in a variety of environments and for various purposes including, but not limited to, adventure activities, sporting, industrial safety, and police or military purposes. In someembodiments, the helmet 10 may be any type of head protection helmet shell known in the art. For example, helmet 10 may be included in a standard infantry ballistic helmet, an advanced combat helmet (ACH) an enhanced combat helmet (ECH), a modular integrated communications helmet (MICH), a tactical ballistic helmet (TBH), a lightweight marine helmet, a police general duty helmet, a personnel armor system for ground troops (PASGT), or an aircrew helmet, such as an HGU-56 / P rotary wing helmet or an HGU 55 / P fixed wing helmet.

[0032] The helmet impact liner 100 may include a shell liner 102 and a first impact attenuation pad 104 coupled thereto. The shell liner 102 may be configured to couple the helmet impact liner to a helmet. The shell liner 102 may be configured to be coupled to the interior surface of a helmet shell. In some embodiments, the shell liner 102 includes mounting elements configured to engage with corresponding fasteners of the helmet 10 such that the shell liner 102 may be coupled to the helmet 10. The shell liner 102 may include one or more apertures 106 for receiving fasteners (e.g., bolts, screws) that may attach the shell liner 102 to the helmet 10. In some embodiments, the shell liner 102 is configured to be detachably coupled to the helmet 10 via hook and loop fastener(s). For example, an outer surface 108 of the shell liner 102 may include one or more loop patches or segments of loops that may be engaged with corresponding hook patches disposed on inner surface of the helmet 10.

[0033] The first impact attenuation pad 104 may provide shock absorption and / or protective functionality to the helmet impact liner. In some embodiments, the first impact attenuation pad 104 is configured to absorb and dissipate the energy from impacts thereby reducing the amount of force transmitted to the wearer’s head 12. In some embodiments, the first impact attenuation pad 104 is detachably coupled to the shell liner 102. For example, the first impact attenuation pad 104 may be detachable from the outer surface 108 of the shell liner 102 such that the first impact attenuation pad 104 and shell liner 102 may be repositioned independent of one another. In some embodiments, the first impact attenuation pad 104 is entirely exterior to the shell liner 102. For example, the first impact attenuation pad 104, when coupled to the shell liner 102 is positioned such that the entirety of the impact attenuation pad 104 is positioned exterior to the shell liner 102. In other embodiments, when coupled to the shell liner 102 the first impact attenuation pad 104 may engage with and / or extend at least partially through the shell liner 102.

[0034] Referring to Figs. 2-3, the first impact attenuation pad 104 may be positioned above the crown of a wearer’s head when in use. The first impact attenuation pad 104 may be positioned within a channel 110 defined by the shell liner 102. In some embodiments, the channel 110 extends between opposed side surfaces of the shell liner 102 and along the crown thereof. For example, thechannel 110 extends from the left side surface (shown in Figs. 2-3) of the shell liner 102, over the crown thereof and to the right-side surface (not shown). The crown of the shell liner 102 may refer to the portion of the shell liner 102 positioned generally directly above the crown of a wearer’s head when in use. The channel 110 may be disposed along the outer surface 108 of the shell liner 102. The channel 110 may be defined by raised surfaces, discussed in more detail below, that are positioned along the outer surface 108 of the shell liner 102. Figs. 2-3 are side elevational views of the helmet impact liner 100 and shell liner 102 respectively and the opposite side elevational views may be mirror images of what is illustrated in Figs. 2-3.

[0035] Referring to Figs. 2 and 4, in some embodiments the helmet impact liner 100 is configured to receive a communications headset 14. In some embodiments, the impact liner 100 may include a fabric layer at least partially encapsulating the shell liner 102. For example, and as illustrated in Fig. 4, the shell liner 102 is encapsulated within a fabric cover. The communications headset 14 may include a headband 16 configured to be placed over the crown of a wearer and one or more earcups 18 attached to terminal ends of the headband 16. In some embodiments, the helmet impact liner 100 is configured to receive a communications headset 14 such that the headband 16 is positioned between the shell liner 102 and first impact attenuation pad 104. As illustrated in Fig. 4, the headband 16 may be positioned within the channel 110 and the first impact attenuation pad 104 may be placed on top of the headband 16 and within the channel 110. Accordingly, the headband 16 may be positioned between the channel 110 and the impact attenuation pad 104. The helmet impact liner 100 of the present disclosure may enable a headset 14 to be securely mounted thereto while simultaneously providing impact attenuation at the crown of the wearer’s head where the headband 16 is positioned. The channel 110 may be sized to enable a headband 16 and the first impact attenuation pad 104 to be positioned therein while the helmet impact liner 100 is coupled to a helmet (e.g., helmet 10). For example, the depth of the channel 110 and the thickness of the impact attenuation pad 104 may be selected such that a when worn with a headset 14 the helmet impact liner 100 substantially conforms to the contour of the inner surface of the helmet to which the liner 100 is coupled to.

[0036] In some embodiments, the helmet impact liner 100 is configured to be coupled to a helmet with or without the communications headset 14 mounted to the liner 100. The first impact attenuation pad 104 may be received within the channel 110 of the shell liner 102 and the shell liner 102 may be coupled to the interior surface of a helmet shell, as discussed above. In such instances, the communications headset may not be mounted to the helmet impact liner 100 and the first impact attenuation pad 104 may be positioned between the channel 110 and the helmet 10. In otherinstances, the communications headset 14 and first impact pad 104 may be mounted to the shell liner 102, as discussed above and illustrated in Fig. 4, and the helmet impact liner 100 with mounted communications headset 14 may be coupled to a helmet 10. In such instances, the headband 16 and first impact pad 104 may be positioned between the channel 110 of the shell liner 102 and the helmet 10 such that the headband 16 is sandwiched between the shell liner 102 and first impact attenuation pad 104.

[0037] Referring to Fig. 5 there is shown a flowchart illustrating a method, generally designated 200, of mounting a communications headset to a helmet impact liner in accordance with an exemplary embodiment of the present disclosure. The method 200 may include the step 202 of positioning a shell liner of a helmet impact liner on a user’s head. For example, the shell liner 102 of helmet impact liner 100 may be positioned on top of a user’s head 12 as illustrated in Fig. 4. The method 200 may include the step 204 of positioning a headband of a communication headset within a channel extending along an outer surface of the shell liner. For example, the headband 16 of headset 14 is positioned within the channel 110 of the shell liner 102 as illustrated in Fig. 4. The method 200 may include the step 206 of positioning a first impact attenuation pad above the headband and within the channel such that the communication headband is sandwiched between the shell liner and the first impact attenuation pad. For example, the first impact attenuation pad 104 may be positioned above the headband 16 within channel 110 such that the headband 16 is sandwiched between the shell liner 102 and the first impact attenuation pad 104 as illustrated in Fig.4.

[0038] Referring to Figs. 6-8, the helmet impact liner 100 may include an adjustment assembly 112 configured to enable a user to adjust the fit of the impact liner 100. In some embodiments, the adjustment assembly 112 is configured to adjust the position of a nape cover 114 of the shell liner 102. The nape cover 114 may extend downwardly from a rear portion 116 of the shell liner 102 opposite a front portion 118 thereof. The rear portion 116 of the shell liner 102 may be the portion of the shell liner 102 that covers the rear of a wearer’s head and the front portion 118 may be the portion that covers the wearer’s forehead. The nape cover 114 may be configured to at least partially cover the nape of a wearer’s neck when in use. For example, the nape cover 114 is positioned along the shell liner 102 such that when worn it extends downwardly from the rear portion 116 and covers at least a portion of a wearer’s nape. In some embodiments, the nape cover 114 is integrally formed with the shell liner 102. For example, the nape cover 114 may be a unitary construct with the shell liner 102.

[0039] The adjustment assembly 112 may include a nape plate 120, a knob 122 rotatably coupled to the nape plate 120 and at least one cable 124 coupled to the knob 122. The nape plate 120 may be configured to be detachably coupled to the shell liner 102 proximate the rear portion 116 thereof. For example, and as illustrated in Fig. 8, the nape plate 120 is mounted to the nape cover 114 of the shell liner 102. The nape plate 120 and / or nape cover 114 may include one or more fasteners for coupling the nape plate 120 to the nape cover 114. For example, the nape plate 120 and nape cover 114 may include corresponding halves of hook and loop fasteners that enable the nape plate 120 to be detachably coupled to the nape cover 114.

[0040] In some embodiments, the nape plate 120 is attachable to the nape cover 114 in a plurality of different positions. The nape plate 120 and nape cover 114 may include fasteners configured to enable the nape plate 120 to be coupled to the nape cover 114 in a plurality of different positions. For example, the outer surface 108 of the shell liner 102 at the nape cover 114 may be substantially covered by a patch, or patches, of loops and the inner surface of the nape plate 120 may include patches of hooks that together form a hook and loop fastener. The surface area of the patches of loops on the shell liner 102 may be greater than that of the patches of hooks of the nape plate 120. Accordingly, the nape plate 120 may be capable of being coupled to the nape cover 114 via the hook and loop fastener in a plurality of different positions. By providing a nape plate 120 that is attachable to the nape cover 114 in a plurality of different positions, the helmet impact line 100 of the present disclosure may enable a user to customize the position of the nape plate 120 as desired when in use.

[0041] Referring to Figs. 7-9, the knob 122 may be configured to enable a user to adjust the position of the nape cover 114. The knob 122 may be rotatably coupled to the nape plate 120 such that rotation of the knob 122 relative to the nape plate 120 causes the nape cover 114 to be moved relative to the front portion 118 of the shell liner 102. The knob 122 may be connected to the cable(s) 124, which may extend from the nape plate 120 to the front portion 118 of the shell liner 102, or proximate thereto. In some embodiments, the cable(s) 124 are fixed at one terminal end to the knob 122 and fixed to the shell liner 102 at the opposite terminal end thereof. For example, a first end of the cable(s) is fixedly coupled to the knob 122 and a second end is fixedly coupled to the shell liner 102. In some embodiments, the adjustment assembly 112 includes two cables 124, each extending from the rear portion 116 of the shell liner 102 along the left and right sides of the shell liner 102 respectively and towards the front portion 118.

[0042] In some embodiments, the cable(s) 124 is / are fixedly coupled to the shell liner 102 via an anchor 126. The anchor 126 may be configured to receive the terminal end of the cable 124 that isopposite to the terminal end connected to the knob 122. In some embodiments, the anchor(s) 126 fixedly couple the terminal end of the cable(s) 124 to the shell liner 102. For example, a terminal end of the cable 124 is fixedly coupled to the corresponding anchor 126 and the anchor is fixedly coupled to the shell liner 102. In some embodiments, the adjustment assembly includes two anchors 126, one for each of the two cables 124. In some embodiments, the anchor(s) are fixedly coupled to the shell liner 102 proximate the front portion 118 thereof (e.g., as illustrated in Fig. 8). In some embodiments, the anchors 126 are fixedly coupled to the shell liner 102 via one or more fasteners. The anchors 126 may be fixedly coupled to the shell liner 102 via straps, adhesives, screws, bolts or the like. For example, and as illustrated in Fig. 9, the anchor 126 is coupled to the shell liner 102 via a plurality of straps 128 that are coupled (e.g., stitched) to the shell liner 102. In some embodiments, the anchor 126 may be detachable from the shell liner 102. In some embodiments, the cable 124 is detachably coupled to the anchor 126. The cable 124 may include a looped end 130 that, when coupled to the anchor 126 wraps around a tooth 132 thereof of the anchor 126. Accordingly, the looped end 130 may be moved into or out of engagement with the tooth 132 as desired in order to couple the cable 124 to the anchor 126.

[0043] In some embodiments, the shell liner 102 may include one or more cable retaining features configured to route the cable(s) 124 from the nape plate 120 to the anchor 126. In some embodiments, the cable(s) 124 may extend at least partially through the shell liner 102. For example, and as illustrated in Fig. 9, a portion of the cable(s) 124 extend through eyelets 134 at the outer surface of the shell liner 102. In some embodiments, at least a portion of the cable(s) 124 extend between the outer surface 108 and an inner surface of the shell liner 102. For example, one or more slots or channels may be formed in the shell liner 102 such that they extend at least partially through the thickness of the shell liner 102. In some embodiments, the slots or channels are positioned along the shell liner 102 between the front portion 118 and rear portion 116 and / or nape cover 114 thereof. Further to this example, the slots or channels may be open along the outer surface 108 and be positioned between the outer surface 108 and opposed inner surface of the shell liner 102.Accordingly, and still further to the above example, the cable(s) 124 may be threaded through the openings and through the channels such that portions of the cables 124 are positioned within the thickness of the shell liner 102 (e g., between outer and inner surfaces thereof).

[0044] In some embodiments, the cables 124 are tensioning cables configured to retain and / or adjust the position of the nape cover 114 relative to the front portion 118 of the shell liner 102. As discussed above the cables 124 may be fixed at opposite ends thereof to the shell liner 102 and knob 122 respectively. Rotation of the knob 122 relative to the nape plate 120 may cause the cable(s) 124at one end to wind around the knob 122 while remaining fixed relative to the shell liner 102 at the opposite end (e.g., via anchor 126). As the cable(s) 124 are wound around the knob 122 the nape plate 120 may move towards the front portion 118 of the shell liner 102, which may cause the nape cover 114 to move with the nape plate 120 towards the front portion 118. Accordingly, rotation of the knob 122 may allow a user to adjust the fit of the shell liner 102 to their head by tightening of the nape cover 114 against their head. For example, and as illustrated in Fig. 9, a user may rotate the knob 122 to tighten the nape cover 114 against their nape.

[0045] Referring to Figs. 2 and 10 the helmet impact liner 100 may include one or more second impact attenuation pads 136 coupled to the shell liner 102. In some embodiments, the second impact attenuation pad(s) may provide shock absorption and / or protective functionality to the helmet impact liner 100. In some embodiments, the second impact attenuation pad(s) 136 is / are configured to absorb and dissipate the energy from impacts thereby reducing the amount of force transmitted to the wearer’s head. In some embodiments, the first and second impact attenuation pads 104, 136 are comprised of the same material. In some embodiments, the first and / or second impact attenuation pads 104, 136 are comprised of a foam material. In some embodiments, the first and / or second impact attenuation pads 104, 136 are comprised of an expanded polypropylene (EPP) foam. IN some embodiments, the first and / or second impact attenuation pads 104, 136 are comprised of an expanded polystyrene (EPS) foam. In some embodiments, the first impact attenuation pad 104 is comprised of a different material than the second impact attenuation pad(s) 136.

[0046] In some embodiments, the shell liner 102 is comprised of the same material as the first and / or second impact attenuation pads 104, 136. In some embodiments, the shell liner 102 is encapsulated in a fabric layer. In some embodiments, the first impact attenuation pad 104 and / or second impact attenuation pads 136 are not encapsulated in the same fabric layer as the shell liner 102. In some embodiments, the shell liner 102 has a thickness that is less than that of the impact attenuation pad 104 and / or impact attenuation pad 136.

[0047] The second impact attenuation pads 136 may be positioned at least partially between the inner surface 138 and outer surface 108 of the shell liner 102. The inner surface 138 of the shell liner 102 may be the surface opposite the outer surface 108, which faces towards the wearer’s head when the helmet impact liner 100 is worn. In some embodiments, the helmet impact liner 100 includes a plurality of second impact pads 136. The plurality of second impact pads 136 may coupled to the shell liner 102 at a plurality of different locations. For example, one or more of the protruding surfaces 140 at the outer surface 108 of the shell liner 102 may correspond to where second impact pads 136 are positioned.

[0048] The second impact pads 136 may be enclosed within chambers 142 defined by the shell liner 102. The chambers 142 may be pockets in the shell liner 102 between the inner surface 138 and outer surface 108 thereof. In some embodiments, second impact pads 136 are entirely enclosed within the chambers 142 of the shell liner 102. For example, the second impact pads 136 are entirely encapsulated between the inner surface 138 and outer surface 108 of the shell liner 102 within chambers 142. In some embodiments, the second impact pads 136 are fixedly coupled to the shell liner 102. For example, the second impact pads 136 are not removable from the shell liner 102 without making openings in the shell liner 102 to the chambers 142 within which the second impact pads 136 are contained.

[0049] In some embodiments, the shell liner 102 is formed via a compression molding process. For example, a liquid foam may be placed into a compression molding apparatus and cured to form the shell liner 102. In some embodiments, the second impact pads 136 may be formed with the shell liner 102 simultaneously. For example, the second impact pads 136 may also be comprised of a foam material that is compression molded along with the shell liner 102. In some embodiments, the shell liner 102 and / or second impact pads 136 are formed by placing pre-cut foam pieces within a compression molding apparatus and executing a compression molding process on the pre-cut foam pieces. In some embodiments, the shell liner 102 may be formed of pre-cut or pre-molded foams that are fastened to one another. For example, the shell liner 102 may be formed by cutting and sewing foam materials together to form the shell liner 102. In such instances, the chambers 142 may be formed during the cutting and sewing process and second impact pads 136 may be placed within the chambers 142 prior to the chambers 142 being sealed (e.g., sewn shut). In other embodiments, the shell liner 102 is comprised of one or more layers of fabric that are sewn together. In such instances, the chambers 142 may be formed by sewing the layers of the fabric together and the second impact pads 136 may be positioned within the chambers 142 prior to the chambers 142 being sealed. In some embodiments, the shell liner 102 is a unitary construct.

[0050] Referring to Figs. 2 and 10-11 the helmet impact liner 100 may include one or more comfort pads 144 configured to receive the head of a wearer. The comfort pads 144 may be detachably coupled to the inner surface 138 of the shell liner 102. For example, the comfort pads 144 are detachably coupled to the inner surface 138 of the shell liner 102 via one or more fasteners (e.g., hook and loop fasteners, snap button fasteners, bolts, screws). In some embodiments, the comfort pads 144 are contoured to generally match the contour of the inner surface 138 of the shell liner 102. The comfort pads 144 may be comprised of an air permeable material that is configured to improve comfort to the wearer of the helmet impact liner 100. For example, the comfort pads 144may be comprised of a mesh material (e.g., a fabric mesh, a 3-D mesh, a spacer fabric) that provides airflow channels and cushioning to the wearer. In some embodiments, the comfort pads 144 are comprised of a softer material than the shell liner 102. In some embodiments, the comfort pads 144 are comprised of an open-pore foam or a reticulated foam. In some embodiments, the comfort pads 144 are comprised of a foam that permits airflow and ventilation. In some embodiments, the comfort pads 144 are comprised of a foam layer that is encapsulated in a fabric permitting airflow to the foam layer.

[0051] In some embodiments, the comfort pads 144 include a tab 146 that wraps around a peripheral edge 148 of the shell liner 102. The tab 146 of the comfort pads 144 may, when the comfort pad 144 is coupled to the shell liner 102 extend around the peripheral edge 148 and contact the outer surface 108 of the shell liner 102. In some embodiments, the tabs 146 aid in retaining the position of the comfort pads 144 relative to the shell liner 102 when coupled thereto. In some embodiments, the tabs 146 are configured to aid a user in decoupling the comfort pads 144 from the shell liner 102. For example, a user may grip the tabs 146 of a comfort pad 144 when decoupling the comfort pad 144 from the shell liner 102. In some embodiments, the tabs 146 include a fastener that couples to the shell liner 102. For example, the tabs 146 may include a layer of a hook and loop fastener that engages with a corresponding fastener proximate the peripheral edge 148 of the shell liner 102. In some embodiments, when the helmet impact liner 100 is coupled to a helmet the tabs 146 may be decoupled from the shell liner 102 and coupled directly to the helmet, thereby improving stability of the fit between the liner 100 and helmet.

[0052] Referring to Figs. 12-15 there is show a helmet impact liner, generally designated 300, in accordance with an exemplary embodiment of the present disclosure. The helmet impact liner 300 may be generally the same as the helmet impact liner 100 except that the second impact pads 336 may be detachably coupled to the shell liner 302. The helmet impact liner 300 may include a shell liner 302 generally the same as shell liner 102 and a first impact attenuation pad 304 that is generally the same as impact attenuation pad 104 discussed above. The first impact attenuation pad 304 may be detachably coupled to the shell liner 302 in generally the same manner as the first impact pad 104 is to the shell liner 102. The first impact attenuation pad 304 may be received within a channel 310 that is generally the same as channel 110.

[0053] In some embodiments, the first impact attenuation pad 304 and channel 310 are configured to receive a communications headset in generally the same manner as the first impact attenuation pad 104 and channel 110. For example, a headband of a communications headset may be positioned within the channel 310 and the first impact pad 304 may be positioned above theheadband within the channel 310 in generally the same manner as described above with regards to Fig. 4. In some embodiments, the method 200 discussed above with regards to Fig. 5 may be performed using the helmet impact liner 300. For example, the steps 202 through 206 of method 200 may be performed using the shell liner 302 and first impact attenuation pad 304 of helmet impact liner 300.

[0054] In some embodiments, the helmet impact liner 300 includes the adjustment assembly 112 or an adjustment assembly substantially similar thereto. The shell liner 302 may include a nape cover 314 that is generally the same as nape cover 114. In some embodiments, the adjustment assembly 112 is coupled to the shell liner 302 in generally the same manner as shell liner 102 and as described above with regards to Figs. 6-9. For example, the nape plate 120 may be coupled to the nape cover 314 and the anchors 126 may fixedly couple one end of the cables 124 to the shell liner 302 proximate a front portion thereof. In some embodiments, the helmet impact liner 300 may include one or more comfort pads that are generally the same as comfort pads 144. For example, comfort pads generally the same as comfort pads 144 may be coupled to the inner surface 338 of the shell liner 302. In other embodiments, the helmet impact liner 300 may not include comfort pads that are generally the same as comfort pads 144.

[0055] In some embodiments, the shell liner 302 defines one or more apertures 335 through which the second impact pads 336 extend. The apertures 335 may extend through the thickness of the shell liner 302 (e.g., from the outer surface 308 to inner surface 338). In some embodiments, the second impact pads 336 are detachably coupled to the shell liner 302 via apertures 335. For example, the second impact pads 336 are removable from the apertures 335 such that they may be decoupled from the shell liner 302. Accordingly, the second impact pads 336 may be easily replaced as desired. For example, a set of second impact pads 336 may be removed from the shell liner 302 and replaced with another set of second impact pads 336, which are attached to the shell liner 302 via apertures 335.

[0056] In some embodiments, the second impact pads 336 extend entirely through the apertures 335 and through the thickness of the shell liner 302. For example, the second impact pads 336 may extend from the outer surface 308, through the apertures 335 and protrude from the inner surface 338 of the shell liner 302. In other embodiments, the second impact pads 336 do not extend beyond the inner surface of the shell liner 302. For example, the second impact pads 336 may extend from the outer surface 308, partially through the apertures 335 and terminate prior to the inner surface 338. In some embodiments, the second impact pads 336 protrude form the outer surface 308 of theshell liner 302. For example, and as illustrated in Figs. 12-15, the second impact pads 336 protrude from the outer surface 308 of the shell liner 302 when coupled thereto via apertures 335.

[0057] The term “about” or “approximately” is used herein to provide literal support for the exact number that it precedes, as well as a number that is near to or approximately the number that the term precedes. In determining whether a number is near to or approximately a specifically recited number, the near or approximating unrecited number may be a number, which, in the context in which it is presented, provides the substantial equivalent of the specifically recited number. It should be appreciated that all numerical values and ranges disclosed herein are approximate values and ranges, whether “about” is used in conjunction therewith. It should also be appreciated that the term “about,” as used herein, in conjunction with a numeral refers to a value that may be ±0.01% (inclusive), ±0.1% (inclusive), ±0.5% (inclusive), ±1% (inclusive) of that numeral, ±2% (inclusive) of that numeral, ±3% (inclusive) of that numeral, ±5% (inclusive) of that numeral, ±10% (inclusive) of that numeral, or ±15% (inclusive) of that numeral. It should further be appreciated that when a numerical range is disclosed herein, any numerical value falling within the range is also specifically disclosed.

[0058] It will be appreciated by those skilled in the art that changes could be made to the exemplary embodiments shown and described above without departing from the broad inventive concepts thereof. It is to be understood that the embodiments and claims disclosed herein are not limited in their application to the details of construction and arrangement of the components set forth in the description and illustrated in the drawings. Rather, the description and the drawings provide examples of the embodiments envisioned. The embodiments and claims disclosed herein are further capable of other embodiments and of being practiced and carried out in various ways.Specific features of the exemplary embodiments may or may not be part of the claimed invention and various features of the disclosed embodiments may be combined. Unless specifically set forth herein, the terms “a”, “an” and “the” are not limited to one element but instead should be read as meaning “at least one”. Finally, unless specifically set forth herein, a disclosed or claimed method should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the steps may be performed in any practical order.

Claims

CLAIMSWhat is claimed is:

1. A helmet impact liner comprising:a shell liner configured to couple the helmet impact liner to a helmet shell, the shell liner including an inner surface and an outer surface and a channel extending along the outer surface; and a first impact attenuation pad detachably coupled to the shell liner and positioned within the channel at the outer surface of the shell liner.

2. The helmet impact liner of claim 1, wherein the shell liner includes a nape cover extending downwardly from a rear portion of the shell liner, and the helmet impact liner further comprises:an adjustment assembly coupled to the nape cover and configured to adjust a position of the nape cover relative to a front portion of the shell liner.

3. The helmet impact liner of claim 2, wherein the adjustment assembly comprises:a nape plate detachably coupled to the nape cover;a knob rotatably coupled to the nape plate; anda cable fixedly coupled to the knob at one terminal end and fixedly coupled to the shell liner at the opposite terminal end.

4. The helmet impact liner of claim 3, wherein the opposite terminal end of the cable is fixedly coupled to the shell liner via an anchor fixedly coupled to the shell liner proximate the front portion thereof.

5. The helmet impact liner of claim 3, wherein the nape plate is attachable to the nape cover in a plurality of different positions.

6. The helmet impact liner of claim 5, wherein the nape plate is detachably coupled to the nape cover via a hook and loop fastener.

7. The helmet impact liner of claim 2, wherein the nape cover is integrally formed with the shell liner.

8. The helmet impact liner of claim 1 further comprising:a second impact attenuation pad coupled to the shell liner and positioned at least partially between the inner surface and outer surface thereof.

9. The helmet impact liner of claim 8, wherein the second impact attenuation pad is detachably coupled to the shell liner.

10. The helmet impact liner of claim 9, wherein the shell liner defines an aperture through which the second impact attenuation pad extends.

11. The helmet impact liner of claim 9, wherein a portion of the second impact attenuation pad protrudes from the outer surface of the shell liner.

12. The helmet impact liner of claim 9, wherein the second impact attenuation pad does not extend beyond the inner surface of the shell liner.

13. The helmet impact liner of claim 8, wherein the second impact attenuation pad is fixedly coupled to the shell liner.

14. The helmet impact liner of claim 13, wherein the shell liner defines a chamber between the outer surface and inner surface thereof and the second impact attenuation pad is entirely enclosed within the chamber.

15. The helmet impact liner of claim 8 further comprising:a plurality of second impact attenuation pads each coupled to the shell liner and positioned at least partially between the inner surface and outer surface of the shell liner.

16. The helmet impact liner of claim 1 further comprising:a comfort pad detachably coupled to the inner surface of the shell liner.

17. The helmet impact liner of claim 16, wherein the comfort pad includes a tab that wraps around a peripheral edge of the shell liner.

18. The helmet impact liner of claim 1, wherein the channel extends along a crown of the shell liner at the outer surface.

19. The helmet impact liner of claim 18, wherein the channel extends between opposed side surfaces of the shell liner and along the crown thereof.

20. The helmet impact liner of claim 1, wherein the first impact attenuation pad is entirely exterior to the shell liner.

21. The helmet impact liner of claim 1, wherein the shell liner is comprised of a fabric material.

22. The helmet impact liner of claim 1, wherein the shell liner is comprised of a foam material.

23. A helmet impact liner comprising:a shell liner configured to couple the helmet impact liner to a helmet shell, the shell liner including an inner surface, an outer surface and a nape cover extending downwardly from a rear portion of the shell liner;an adjustment assembly coupled to the nape cover and configured to adjust a position of the nape cover relative to a front portion of the shell liner;a first impact attenuation pad detachably coupled to the shell liner at the outer surface thereof;a second impact attenuation pad coupled to the shell liner and positioned at least partially between the shell liner between the inner surface and outer surface thereof; anda comfort pad detachably coupled to the inner surface of the shell liner.

24. A method of mounting a communication headset to a helmet impact liner, the method comprising:positioning a shell liner of a helmet impact liner on a user’s head;positioning a headband of a communication headset within a channel extending along an outer surface of the shell liner; andpositioning a first impact attenuation pad above the headband and within the channel such that the headband is sandwiched between the shell liner and first impact attenuation pad.

25. The method of claim 24, wherein the channel extends between opposed side surfaces of the shell liner and along a crown thereof.

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