IP Verse

Multi-Layer Helmet And Method For Making The Same

Patent No. US11291263 (titled "Multi-Layer Helmet And Method For Making The Same") was filed by Capital One Na on Jul 29, 2019.

What is this patent about?

’263 is related to the field of protective helmets, specifically those used in sports. Conventional helmets often consist of a single layer of energy-absorbing material, typically expanded polystyrene (EPS). These single-layer designs provide energy dissipation through deformation but lack flexibility and may not conform well to individual head shapes, leading to gaps and pressure points. This patent addresses the need for improved energy management and a more customized fit in protective helmets.

The underlying idea behind ’263 is to use a multi-layer liner within the helmet shell to better manage impact energy. Instead of a single density material, the helmet uses layers with different densities and mechanical properties. This allows the helmet to address different impact energies more effectively, with a denser outer layer for high-energy impacts and a less dense inner layer for lower-energy impacts. The layers are designed to allow relative rotational movement between them, further dissipating energy during an impact.

The claims of ’263 focus on a protective helmet with an outer shell and a multi-layer liner assembly. The liner includes an inner-layer made of a first material with a first density and an outer-layer made of a second material with a second, higher density. The key feature is that the multi-layer liner assembly allows for relative rotational movement between the layers upon impact. Furthermore, the outer-layer has a variable thickness between the front and crown regions, and the inner-layer is mechanically secured without adhesive.

In practice, the multi-layer liner is constructed with specific materials and densities tailored to different impact scenarios. For example, the outer-layer might be made of EPS, the middle-layer of EPO, and the inner-layer of EPP, each with a specific density range. The layers are mechanically coupled, allowing them to move relative to each other without adhesive bonding. This relative movement helps to dissipate rotational forces during an impact, reducing the risk of concussion.

The design differentiates itself from traditional helmets by using multiple layers optimized for different energy levels, rather than a single layer attempting to handle all impacts. The variable thickness of the outer layer and the segmented, flexible design of the inner layer further enhance the helmet's ability to conform to different head shapes and manage impact forces. The mechanical coupling without adhesives also promotes relative movement between layers, a feature absent in many conventional designs.

How does this patent fit in bigger picture?

Technical landscape at the time

In the early 2010s when ’263 was filed, helmet design at a time when multi-layer construction was typically implemented using different materials to manage energy from impacts. At this time, helmet designs commonly relied on specific material densities and thicknesses to achieve desired protective characteristics, when hardware or software constraints made precise customization of helmet liners non-trivial.

Novelty and Inventive Step

The claims were rejected under 35 U.S.C. 112(b) as being indefinite. Claims were also rejected under 35 U.S.C. 103 as being unpatentable over prior art references. Claims were rejected on the ground of nonstatutory double patenting. The prosecution record does NOT describe the technical reasoning or specific claim changes that led to allowance.

Claims

This patent contains 21 claims, with independent claims 1 and 13. The independent claims are directed to protective sports helmets having a multi-layer liner assembly with inner and outer layers. The dependent claims generally elaborate on the features, materials, and configurations of the layers within the helmet.

Key Claim Terms New

Definitions of key terms used in the patent claims.

Term (Source)Support for SpecificationInterpretation
First density
(Claim 1)		“In one aspect, a protective helmet can comprise a multi-layer liner comprising a high-energy management material comprising a density in a range of 20-50 g/L, a mid-energy management material comprising a density in a range of 40-70 g/L, and a low-energy management material comprising a density in a range of 10-20 g/L. The mid-energy management material can comprise EPS or expanded polyolefin (EPO) with a density of 20-40 g/L, or expanded polypropylene (EPP) with a density of 30-50 g/L.”The density of the first material used to make the inner-layer of the multi-layer liner assembly.
Flexible outer shell
(Claim 13)		“The protective helmet can comprise a cycling helmet, and the outer shell can comprise a stamped, thermoformed, or injection molded polycarbonate shell. The protective helmet comprises a cycling helmet further comprising an outer shell formed of a stamped, thermoformed, or injection molded polycarbonate shell.”An outer shell of the protective sports helmet that is flexible.
Multi-layer liner assembly
(Claim 1, Claim 13)		“In one aspect, a protective helmet can comprise an outer shell, and a multi-layer liner disposed within the outer shell and sized for receiving a wearer's head. The multi-layer liner can comprise an inner-layer comprising an inner surface oriented towards an inner area of a helmet for a wearer's head, wherein the inner-layer comprises a mid-energy management material with a density in a range of 40-70 g/L. The multi-layer liner can also comprise a middle-layer disposed adjacent an outer surface of the inner-layer, wherein the middle-layer comprises a low-energy management material with a density in a range of 10-20 g/L. The multi-layer liner can also comprise an outer-layer disposed adjacent an outer surface of the middle-layer, the outer-layer comprising an outer surface oriented towards the outer shell, wherein the outer-layer comprises a high-energy management material with a density in a range of 20-50 g/L.”A liner within the helmet's outer shell, composed of at least an inner and outer layer, that allows relative rotational movement between the layers upon impact.
Relative rotational movement
(Claim 1, Claim 13)		“For particular implementations, the middle-layer can comprise a thickness in a range of 5-7 millimeters (mm) and be coupled to the inner-layer and the outer-layer without adhesive to facilitate relative movement among the inner-layer, the middle-layer, and the outer-layer. The middle-layer can be mechanically coupled to the inner-layer and the outer-layer to allow for relative movement among the middle-layer, inner-layer, and outer-layer. At least one padding snap can be coupled to the multi-layer liner to facilitate relative movement between the high-energy management material, the low-energy management material, and the a mid-energy management material.”The ability of the layers within the multi-layer liner assembly to move rotationally relative to each other when the helmet is worn and receives an impact.
Second density
(Claim 1)		“In one aspect, a protective helmet can comprise a multi-layer liner comprising a high-energy management material comprising a density in a range of 20-50 g/L, a mid-energy management material comprising a density in a range of 40-70 g/L, and a low-energy management material comprising a density in a range of 10-20 g/L. For particular implementations, the low-energy management material comprises a density in a range of 10-20 g/L, and the high-energy management material can comprise a density in a range of 20-50 g/L.”The density of the second material used to make the outer-layer of the multi-layer liner assembly, which is greater than the first density.

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US11291263

CAPITAL ONE NA
Application Number
US16525263
Filing Date
Jul 29, 2019
Status
Granted
Expiry Date
Sep 4, 2035
External Links
Slate, USPTO, Google Patents