Helmet impact liner system

Abstract

The present application discloses a helmet and an impact liner system and energy management structures for a helmet. In one exemplary embodiment, the impact liner system comprises a plurality of compressible energy management structures and one or more carriers for supporting the plurality of energy management structures within a helmet shell. The energy management structures are positioned between an interior surface of the helmet shell and the head of a user when the impact liner system is attached to the helmet shell. Each energy management structure comprises an outer wall configured to bend when an exterior of the helmet shell is impacted by an object. The carrier comprises a plurality of openings configured to receive the energy management structures. The outer wall of the energy management structures extend between the interior of the helmet shell and the carrier of the impact liner system.

We claim: 
     
         1 . An impact liner system for a helmet shell, comprising:
 a plurality of compressible energy management structures positioned between an interior surface of a helmet shell and the head of a user when the impact liner system is attached to the helmet shell, wherein each energy management structure comprises an outer wall configured to bend when an exterior of the helmet shell is impacted by an object; and   one or more carriers for supporting the plurality of energy management structures within the helmet shell, the carrier comprising a plurality of openings, each opening configured to receive an energy management structure; and   wherein the outer wall of the energy management structures extend between the interior of the helmet shell and the carrier of the impact liner system.   
     
     
         2 . The impact liner system of  claim 1 , wherein the outer wall of the energy management structures is cylindrical. 
     
     
         3 . The impact liner system of  claim 1  further comprising one or more pads positioned between the energy management structures and the head of the user. 
     
     
         4 . The impact liner system of  claim 1 , wherein the energy management structures comprise a flange for positioning the energy management structures within the openings of the carrier. 
     
     
         5 . The impact liner system of  claim 3 , wherein the flange is a radial flange extending outward from the outer wall and about a centerline of the energy management structure. 
     
     
         6 . The impact liner system of  claim 1 , wherein the energy management structures are removably attached in the openings of the carrier. 
     
     
         7 . The impact liner system of  claim 6 , wherein the energy management structures comprise one or more resilient protrusions extending from the outer wall that permit the energy management structures to snap into the openings of the carrier. 
     
     
         8 . The impact liner system of  claim 1 , wherein the outer wall of one or more of the energy management structures is cylindrical, and wherein one or more resilient protrusions extend outward from the cylindrical outer wall, and wherein an edge of the opening in the carrier is positioned between the one or more protrusions and a flange of the energy management structure when the energy management structure is received in the opening. 
     
     
         9 . The impact liner system of  claim 1 , wherein the impact liner system is configured such that a top wall of one or more of the energy management structures is positioned facing the user's head. 
     
     
         10 . The impact liner system of  claim 1 , wherein the impact liner system is configured such that a top wall of one or more of the energy management structures is positioned facing the interior surface of a helmet shell. 
     
     
         11 . The impact liner system of  claim 1 , wherein one or more of the energy management structures is removably attached to the interior surface of the helmet shell to attach the impact liner system to the helmet shell. 
     
     
         12 . The impact liner system of  claim 1 , wherein a draft angle between the outer wall of one or more of the energy management structures and a vertical axis is between 0 degrees and about 3 degrees. 
     
     
         13 . The impact liner system of  claim 1 , wherein the diameter of one or more of the energy management structures is between about 0.5 inch and about 1.5 inch. 
     
     
         14 . The impact liner system of  claim 1 , wherein the height of one or more of the energy management structures is between about ⅜ inch and about 1 inch. 
     
     
         15 . The impact liner system of  claim 1 , wherein the energy management structures comprise thermoplastic polyurethane. 
     
     
         16 . The impact liner system of  claim 1 , wherein the thickness of the outer wall of one or more of the energy management structures is between about 0.01 inch and about 0.05 inch. 
     
     
         17 . The impact liner system of  claim 1 , wherein the thickness of the outer wall of one or more of the energy management structures is about 0.03 inch. 
     
     
         18 . The impact liner system of  claim 1 , wherein one or more of the energy management structures comprise a top wall having one or more openings. 
     
     
         19 . A helmet, comprising:
 a helmet shell; and   an impact liner system removably attached to the helmet shell, the impact liner system comprising a plurality of compressible energy management structures and one or more carriers for supporting the energy management structures within the helmet shell;   wherein the plurality of compressible energy management structures are positioned between an interior surface of the helmet shell and the head of a user when the impact liner system is attached to the helmet shell, and wherein each energy management structure comprises an outer wall configured to bend when an exterior of the helmet shell is impacted by an object; and   wherein the one or more carriers comprise a plurality of openings, each opening configured to receive an energy management structure, and wherein the outer wall of the energy management structures extend between the interior of the helmet shell and the carrier of the impact liner system.   
     
     
         20 . The helmet of  claim 19 , wherein the outer wall of the energy management structures is cylindrical. 
     
     
         21 . The helmet of  claim 19 , wherein the impact liner system comprises one or more pads positioned between the energy management structures and the head of the user. 
     
     
         22 . An energy management structure for a helmet, comprising:
 a top wall;   an outer wall extending from the top wall and about a centerline of the energy management structure; and   a radial flange extending outward from the outer wall and about the centerline of the energy management structure;   wherein the energy management structure is configured to be positioned between the head of user and an interior surface of a helmet shell such that the top wall is adjacent the head of the user and a bottom of the outer wall is adjacent the interior surface, and wherein the outer wall is configured to bend when an exterior of the helmet shell is impacted by an object.   
     
     
         23 . The energy management structure of  claim 22 , wherein the outer wall is cylindrical. 
     
     
         24 . The energy management structure of  claim 22  further comprising one or more protrusions extending outward from the outer wall. 
     
     
         25 . The energy management structure of  claim 22  further comprising one or more pads attached to the top wall. 
     
     
         26 . The energy management structure of  claim 22 , wherein the top wall comprises one or more openings.