Protective Helmets

Abstract

Embodiments of a protective helmet have a shell formed from a cushioning material, a cushioning spacer layer coupled to the shell and only partially covering an inner surface of the shell, and a hard inner structure having an outer surface attached to the cushioning spacer layer and an inner surface. An innermost cushioning pad layer may be attached to the inner surface of the hard inner structure. A flexible thin cover extending around an outer surface of said shell and with or without graphics may be provided.

1 . A protective helmet comprising:
 a continuous cushioning shell layer formed from a cushioning material and having an inner surface;   a cushioning spacer layer contacting said inner surface of said shell layer, said cushioning spacer layer only partially covering said inner surface of said shell and including cushioning structure defining gaps; and   a hard inner structure having an outer surface and an inner surface, said outer surface of said hard inner structure attached to said cushioning spacer layer, said hard inner structure formed from material that is substantially harder than said cushioning material of said shell layer and said cushioning structure of said cushioning spacer layer.   
     
     
         2 . A protective helmet according to  claim 1 , further comprising: an innermost cushioning pad layer attached to said inner surface of said hard inner structure. 
     
     
         3 . A protective helmet according to  claim 2 , wherein: at least one of said shell and said cushioning spacer layer are formed from foam. 
     
     
         4 . A protective helmet according to  claim 3 , wherein: said hard inner structure is formed from at least one polycarbonate, hard plastic, ABS resin, polypropylene, carbon fiber, fiberglass, para-aramid synthetic fiber, and ultra-high-molecular-weight polyethylene. 
     
     
         5 . A protective helmet according to  claim 4 , wherein: said hard inner structure defines a plurality of cut-outs or includes a plurality of horizontal frame members and a plurality of lateral frame members that define spaces. 
     
     
         6 . A protective helmet according to  claim 4 , wherein: said hard inner structure is continuous. 
     
     
         7 . A protective helmet according to  claim 4 , wherein: said cushioning spacer layer comprises one spacer. 
     
     
         8 . A protective helmet according to  claim 7 , wherein: said one spacer has a plurality of grooves defining spacer areas connected by an inner spacer layer, said inner spacer layer substantially completely covering said outer surface of said hard inner structure. 
     
     
         9 . A protective helmet according to  claim 4 , wherein: said cushioning spacer layer comprises a plurality of separate spacers. 
     
     
         10 . A protective helmet according to  claim 1 , further comprising: a flexible thin cover extending around an outer surface of said cushioning shell layer and constituting an outermost layer of said protective helmet. 
     
     
         11 . A protective helmet according to  claim 10 , wherein: said flexible thin cover comprises one of a fabric, film and foil, leather, artificial leather, ballistic nylon, polychloroprene, polyester fabric, para-aramid synthetic fiber, and ultra-high-molecular-weight polyethylene. 
     
     
         12 . A protective helmet according to  claim 10 , wherein: said flexible thin cover is adapted to be removable from said shell without damaging said shell. 
     
     
         13 . A protective helmet, comprising:
 a continuous shell formed from a resilient cushioning foam material, said continuous shell having an outer surface and an inner surface;   a flexible thin cover extending around said outer surface of said shell;   a cushioning foam spacer layer contacting and only partially covering said inner surface of said shell, said cushioning spacer layer including at least one resilient pad defining first spaces;   a hard inner structure having an outer surface attached to said cushioning foam spacer layer, and an inner surface, said hard inner structure being substantially harder than said shell and said cushioning foam spacer layer, and said hard inner structure defining second spaces;   an innermost cushioning pad layer attached to said inner surface of said hard inner structure and formed from foam elements.   
     
     
         14 . A protective helmet according to  claim 13 , wherein: said hard inner structure is formed from at least one polycarbonate, hard plastic, ABS resin, polypropylene, and fiberglass, and said innermost cushioning pad layer comprises a plurality of innermost pads defining third spaces therebetween. 
     
     
         15 . A protective helmet, according to  claim 2 , wherein:
 said continuous cushioning shell is formed from at least one of foam and resilient thermoplastic polyurethane, said continuous cushioning shell having a convex outer surface and a concave inner surface;   said cushioning spacer layer including at least one pad defining first spaces and formed from at least one of foam and resilient thermoplastic polyurethane;   said hard inner structure comprising a continuous ballistic-resistant inner shell having a convex outer surface and a concave inner surface, said convex outer surface of said ballistic-resistant inner shell attached to said cushioning spacer layer and formed from at least one of a para-aramid synthetic fiber and ultra-high-molecular-weight polyethylene;   said innermost cushioning pad layer formed from at least one of foam, resilient thermoplastic polyurethane, and open-cell polyurethane.   
     
     
         16 . A protective helmet according to  claim 15 , further comprising: a flexible thin cover extending around said outer convex surface of said cushioning shell. 
     
     
         17 . A protective helmet according to  claim 16 , wherein: said flexible thin cover is adapted to camouflage said helmet. 
     
     
         18 . A protective helmet, comprising:
 a continuous shell formed from a resilient cushioning foam material, said continuous shell having an outer surface and an inner surface;   a flexible thin cover extending around said outer surface of said shell;   a cushioning foam spacer layer contacting and only partially covering said inner surface of said shell, said cushioning spacer layer including at least one resilient foam pad; and   a hard inner structure having an outer surface attached to said cushioning foam spacer layer, and an inner surface, said hard inner structure being substantially harder than said shell and said cushioning foam spacer layer.   
     
     
         19 . A protective helmet according to  claim 18 , wherein: said cushioning foam spacer layer is formed from sheet material with a central area, and a plurality of petals extending from said central area, said central area and said plurality of petals including a plurality of grooves. 
     
     
         20 . A protective helmet according to  claim 18 , wherein: said cushioning foam spacer layer is formed from open cell polyurethane microcellular foam having a Shore A hardness of at most 30, and said hard inner structure is formed from carbon fiber.