Helmet with shock absorbing inserts

Abstract

Helmets and methods for manufacturing a helmet are described. An example helmet includes a shell and a shock absorbing liner attached to the shell. The shock absorbing liner includes a cavity. The helmet a shock absorbing insert formed of a material different than the material of the shock absorbing liner. The cavity is configured to retain the shock absorbing insert.

What is claimed is: 
     
         1 . A helmet comprising:
 a shell;   a liner coupled to the shell and defining a liner cavity; and   a cellular insert received within and filling the liner cavity; wherein:
 the cellular insert comprises a plurality of energy absorbing cells; and 
 the liner and the cellular insert together define an interior surface of the helmet. 
   
     
     
         2 . The helmet of  claim 1 , wherein the cellular insert defines at least 50% of an area of the interior surface of the helmet. 
     
     
         3 . The helmet of  claim 1 , wherein the liner cavity and the cellular insert are shaped such that the cellular insert is compressed to insert the cellular insert into the liner cavity or remove the cellular insert from the liner cavity. 
     
     
         4 . The helmet of  claim 1 , wherein:
 the liner is seamless and comprises a plurality of closed cells; and   the plurality of energy absorbing cells comprises open cells.   
     
     
         5 . The helmet of  claim 1 , wherein:
 each of the cells of the plurality of energy absorbing cells is arranged to have a first end facing towards an exterior of the helmet and a second end facing towards an interior of the helmet; and   longitudinal axes of the cells are arranged at angles between 0° and 45° of normal to points on the interior surface of the shell adjacent to the respective cells.   
     
     
         6 . The helmet of  claim 1 , wherein:
 the liner cavity is configured to receive the cellular insert in an arched configuration such that a first length of a curved surface of the cellular insert proximal the shell is greater than a second length of a curved surface of the cellular insert distal the shell; and   a shape of the cellular insert matches a shape of the liner cavity.   
     
     
         7 . A helmet, comprising:
 a shell comprising a first vent defining a first opening;   a liner adjacent to and attached to the shell, the liner comprising a cavity at least partially aligned with the first vent; and   an insert comprising a plurality of cells;   wherein:
 a first plurality of the cells engages interior sidewalls of the cavity; 
 the insert spans across at least a portion of the first vent; 
 at least a portion of the liner is positioned between the shell and the insert; and 
 the cells comprise tubular structures. 
   
     
     
         8 . The helmet of  claim 7 , wherein longitudinal axes of the tubular structures are arranged at angles between 0° and 45° of lines normal to points on an inner surface of the shell adjacent to the respective tubular structures. 
     
     
         9 . The helmet of  claim 7 , wherein the cells have regular or irregular geometries. 
     
     
         10 . The helmet of  claim 7 , wherein:
 the shell further comprises a second vent defining a second opening;   the cavity is at least partially aligned with the second vent; and   the first vent and the second vent are arranged symmetrically in the shell.   
     
     
         11 . The helmet of  claim 7 , wherein an angle between a side surface of the liner defining a perimeter of the cavity and a surface of the liner adjacent to the side surface and further defining the cavity is 90 degrees or less. 
     
     
         12 . The helmet of  claim 7 , wherein:
 an inner surface of the helmet is defined by the liner and the insert; and   the insert defines at least 50% of an area of the inner surface of the helmet.   
     
     
         13 . A helmet, comprising:
 a shell;   a liner adjacent to and attached to the shell, the liner defining a liner cavity; and   an insert comprising an array of cells positioned in and substantially filling the liner cavity;   wherein:
 a shape of the insert relative to a shape of the liner cavity is configured such that the insert is deformed in order to be inserted into or removed from the liner cavity; 
 the shape of the liner cavity is configured to retain the insert based on an expansion pressure of sides of the insert against sides of the liner defining the liner cavity. 
   
     
     
         14 . The helmet of  claim 13 , wherein the insert has a curved shape substantially corresponding to a curved interior surface of the liner cavity when the insert is arranged in the liner cavity. 
     
     
         15 . The helmet of  claim 13 , wherein each of the cells of the array of cells comprises a hollow tube. 
     
     
         16 . The helmet of  claim 13 , wherein:
 the shell comprises a first vent opening;   a first set of cells of the array of cells is at least partially aligned with and at least partially visible through the first vent opening; and   the first set of cells allows air to enter through the first vent opening and pass through toward an interior of the helmet.   
     
     
         17 . The helmet of  claim 13 , wherein an angle between a bottom surface of the liner cavity and a side surface of the liner cavity is 90 degrees or less. 
     
     
         18 . The helmet of  claim 13 , wherein the insert has a thickness less than or equal to the liner. 
     
     
         19 . The helmet of  claim 13 , wherein the curved interior surface of the helmet is defined by the liner and the insert. 
     
     
         20 . The helmet of  claim 13 , wherein a surface of the liner opposite the shell outside the liner cavity is flush with a surface of the insert opposite the shell.