Helmet with floating shell plates

Abstract

A football helmet comprises a plastic shell having a recess formed in the shell, a shock absorbing pad in the recess and removably connected to the shell, and a floating shell plate removably attached to the shock absorbing pad and further connected to the shell by a tab-slot engagement. The helmet may further comprise an inner liner comprising a shock absorbing element, an inflatable liner element, and a mobility layer disposed between the shock absorbing element and the inflatable liner element, the mobility layer having a plurality of raised elements formed therein to separate the shock absorbing element from the mobility layer thereby forming a gap between the shock absorbing element and the mobility layer, enabling relative movement of the inflatable liner with respect to shock absorbing element.

1 . (canceled) 
     
     
         2 . A helmet comprising:
 a shell comprising an outer surface and an inner surface;   wherein at least one recess is formed in the outer surface of the shell, the at least one recess having a floor that is lower relative to portions of the outer surface that are adjacent to the at least one recess;   a shock absorbing cushion removably attached to the at least one recess, wherein the shocking absorbing cushion; and   a resilient shell plate removably attached to the outer surface and configured to cover the at least one recess and the shock absorbing cushion, wherein the resilient shell plate is configured to move and the shock absorbing cushion is configured to deform when an external force is applied to the resilient shell plate.   
     
     
         3 . The helmet of  claim 2 , wherein the shock absorbing cushion comprises thermoplastic polyurethane (TPU). 
     
     
         4 . The helmet of  claim 2 , wherein the at least one recess comprise a first recess located at the apex of the outer surface, and a second recess located at a rear region of the outer surface, which corresponds to a rear portion of a head of a wearer when the wearer's head is received a cavity defined by the helmet. 
     
     
         5 . The helmet of  claim 2 , wherein the shock absorbing cushion comprises a first through-going hole, and the resilient shell plate comprises a second through-going hole, and wherein the first through-going hole and the second through-going hole are vertically aligned to receive a screw or bolt to removably attach the shock absorbing cushion and the resilient shell plate to the shell. 
     
     
         6 . The helmet of  claim 2 , wherein shocking absorbing cushion comprises:
 a base sheet, and   one or more impact absorbing structures coupled to the based sheet, wherein the one or more impact absorbing structures are configured to deform when the external force is applied to the resilient shell plate,   wherein the one or more impact absorbing structures comprise a plurality of domes in a first set of rows, and a plurality of cups in a second set of rows, wherein the first set of rows and the second set of rows are alternatively arranged on the base sheet.   
     
     
         7 . The helmet of  claim 2 , further comprising:
 a plurality of banks that surround the recess and at least one bank of the plurality of banks defines a first slot; and   the shell plate comprises a first tab engaging with the first slot.   
     
     
         8 . The helmet of  claim 2 , further comprising a shock absorbing assembly removably attached to the inner surface of the shell, wherein the shock absorbing assembly comprises:
 a shock absorbing element removably attached to the inner surface of the shell, the shock absorbing element comprising:
 a base sheet having a first surface, and a second surface facing opposite to the first surface, and 
 a plurality of hollow projections on the first surface extending away from the base sheet, wherein at least one free end of the plurality of hollow projections contacts the inner surface of the shell; 
   a mobility layer movably contacting the second surface of the shock absorbing element; the mobility layer comprising:
 a plurality of raised elements on at least one side of the mobility layer, wherein at least one of the plurality of raised elements contacts the second surface of the shock absorbing element; and 
   an inflatable liner element contacting the mobility layer, the inflatable liner element comprising a plurality of pressurized cells extending away from the inflatable liner element, wherein at least one of the plurality of the pressurized cells contacts a wearer's head when the wearer's head is received in a cavity defined by the helmet.   
     
     
         9 . The element of  claim 8 , wherein at least one of the plurality of hollow projections comprises an opening free end, the opening free end allowing a T-nut to removably attach the shock absorbing element with the inner surface of the shell. 
     
     
         10 . The element of  claim 8 , wherein the at least one of the plurality of raised elements form a gap between the mobility layer and the shock absorbing element, the gap allowing the inflatable liner element to move relative to the shock absorbing element so that under an external force, the inflatable liner element moves or rotates a less amount than the shock absorbing element. 
     
     
         11 . The helmet of  claim 8 , wherein the shock absorbing element comprises thermoplastic polyurethane (TPU). 
     
     
         12 . The helmet of  claim 8 , wherein two neighboring hollow projections of the plurality of hollow projections are connected by a connecting rib. 
     
     
         13 . The helmet of  claim 8 , wherein the at least one free end of the plurality of hollow projections is a closed end. 
     
     
         14 . The helmet of  claim 8 , wherein free ends of the plurality of hollow projections are tapered. 
     
     
         15 . The helmet of  claim 8 , wherein the pressurized cells are in fluid communication with one another, and wherein the inflatable liner element further comprises a valve through which to inflate or deflate the pressurized cells. 
     
     
         16 . The helmet of  claim 8 , further comprising a pad removable attached to the shock absorbing element to form a front pad, wherein the front pad is positioned at a location over a front edge of the shell, the location corresponding to a forehead of a wearer when the wearer's head is received in the cavity. 
     
     
         17 . The helmet of  claim 16 , wherein the pad comprises thermoplastic polyurethane (TPU) or ethylene-vinyl acetate material (EVA). 
     
     
         18 . The helmet of  claim 16 , wherein the pad defines a plurality of passages, each of the plurality of passages corresponding to a hollow projection of the plurality of hollow projections of the shock absorbing element, and wherein the plurality of passages are shaped to provide a friction fit or interference fit between internal surfaces of the plurality of passages and external surfaces of the plurality of hollow projections. 
     
     
         19 . The helmet of  claim 18 , wherein the pad comprises a thick region and a thin region, the plurality of passaged included in the thin region. 
     
     
         20 . The helmet of  claim 19 , wherein the thick region and the thin region defines a recess for receiving the shock absorbing element when the plurality of hollow projections snuggly fit in the plurality of passages. 
     
     
         21 . The helmet of  claim 2 , further comprising a face guard removably attached to the shell.