USRE48769E1 - Adjustable hockey helmet - Google Patents

Abstract

An adjustable hockey helmet includes a front shell that is longitudinally movable relative to a rear shell to adjust the length of the helmet. One or more substantially rigid straps or similar elements are attached to the front shell and extend to the interior of the rear shell. A cam mechanism or similar device is included on the rear shell for securing the straps directly or indirectly against the interior of the rear shell to prevent longitudinal movement of the front shell relative to the rear shell once the helmet is adjusted to a desired length. Alternatively, the one or more straps may be attached to the rear shell and the cam mechanism may be included on the front shell.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

Notice: More than one reissue application has been filed for the reissue of U.S. Pat. No. 8,832,870. The reissue applications are application Ser. No. 16/867,511 (the present application), filed May 5, 2020, application Ser. No. 15/904,016, filed Feb. 23, 2018, which issued as U.S. Pat. No. RE48,048, and application Ser. No. 15/268,127, filed Sep. 16, 2016, which issued as U.S. Pat. No. RE47,747. This application is a continuation reissue of application Ser. No. 15/904,016 (now U.S. Pat. No. RE48,048), which is a continuation reissue of application Ser. No. 15/268,127 (now U.S. Pat. No. RE47,747), which is a reissue of U.S. Pat. No. 8,832,870 (application Ser. No. 13/654,260, filed Oct. 17, 2012), which is a continuation of U.S. patent application Ser. No. 12/191,000 (now U.S. Pat. No. 8,296,868), filed Aug. 13, 2008, which claims priority to U.S. Provisional Patent Application No. 60/956,621, filed Aug. 17, 2007, bothall of which are hereby incorporated by reference.

BACKGROUND

Adjustable hockey helmets are used to accommodate various head sizes of wearers. A typical adjustable hockey helmet includes a front shell that is movable or slidable relative to a rear shell to adjust the length of the helmet. Cam mechanisms or other locking devices are commonly included on the sides of the helmet to securely engage the front shell against the rear shell to prevent longitudinal movement of the shells relative to each other once the helmet is adjusted to the desired length. While existing adjustable hockey helmets have been relatively effective, it would be advantageous to have a hockey helmet that is more readily adjustable and that can more easily be secured in place.

SUMMARY

An adjustable hockey helmet includes a front shell that is longitudinally movable relative to a rear shell to adjust the length of the helmet. One or more substantially rigid straps or similar elements are attached to the front shell and extend to the interior of the rear shell. A cam mechanism or similar device is included on the rear shell for securing the straps directly or indirectly against the interior of the rear shell to prevent longitudinal movement of the front shell relative to the rear shell once the helmet is adjusted to a desired length. Alternatively, the one or more straps may be attached to the rear shell and the cam mechanism may be included on the front shell.

Other features and advantages will appear hereinafter. The features described above can be used separately or together, or in various combinations of one or more of them.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, wherein the same reference number indicates the same element throughout the several views:

FIG. 1 is an exterior perspective view of an adjustable hockey helmet according to one embodiment.

FIG. 2 is an interior perspective view of the helmet shown inFIG. 1.

FIG. 3 is an interior perspective view of the helmet shown inFIGS. 1 and 2, with the interior padding removed to reveal elements positioned between the padding and the interior surface of the helmet.

FIG. 4A is a rear perspective view of the helmet shown inFIGS. 1-3 with the cam mechanism in the closed or locked position.

FIG. 4B is a side perspective view of the rear shell of the helmet shown inFIGS. 1-4 with the cam mechanism in the open or unlocked position.

FIG. 5 is a perspective view of a side plate included on the helmet shown inFIGS. 1-4.

FIG. 6 is a perspective view of a side strap of the longitudinal adjustment mechanism included in the helmet shown inFIGS. 1-4.

FIG. 7 is a perspective view of the side strap shown inFIG. 6 attached to the side plate shown inFIG. 5 with the other helmet elements removed for clarity.

FIG. 8 is a side-perspective view of a cam mechanism included in the helmet shown inFIGS. 1-4.

FIG. 9 is a rear perspective view of the cam mechanism shown inFIG. 8.

FIG. 10 is a perspective view of the longitudinal adjustment mechanism included in the helmet shown inFIGS. 1-4, including adjustment straps and the cam mechanism shown inFIGS. 8 and 9.

FIG. 11 is a perspective view of a lateral and occipital adjustment system included in the helmet shown inFIGS. 1-4.

FIG. 12 is a perspective view of the longitudinal, lateral, and occipital adjustment systems included in the helmet shown inFIGS. 1-4.

FIG. 13 is a perspective view of a height-adjustable earpiece and a clamping plate included in the helmet shown inFIGS. 1-4.

FIG. 14 is a perspective view of a height-adjustable J-clip included in the helmet shown inFIGS. 1-4.

FIG. 15 is a perspective view of an ear-loop included in the helmet shown inFIGS. 1-4.

FIG. 16 is a perspective view of an interior region of a front plate included in the helmet shown inFIGS. 1-4.

FIG. 17A is a perspective view of one embodiment of a front screw-plate that may be included in the helmet shown inFIGS. 1-4.

FIG. 17B is a perspective view of an alternative embodiment of a front screw-plate that may be included in the helmet shown inFIGS. 1-4.

FIG. 18 includes multiple perspective views of a magnetic buckle optionally included on the helmet shown inFIGS. 1-4.

FIG. 19 includes multiple perspective views of a wire face-mask and height-adjustable chin cup optionally included on the helmet shown inFIGS. 1-4.

FIG. 20 includes multiple sectional views of a locking tab optionally included in the helmet shown inFIGS. 1-4.

FIG. 21 is a perspective view of a comfort nose-pad optionally included in the helmet shown inFIGS. 1-4.

FIG. 22 includes multiple views of a head-form optionally included in helmet packaging.

FIG. 23 includes multiple views of a helmet packaging assembly, including the head-form shown inFIG. 22.

DETAILED DESCRIPTION OF THE DRAWINGS

Various embodiments of the invention will now be described. The following description provides specific details for a thorough understanding and enabling description of these embodiments. One skilled in the art will understand, however, that the invention may be practiced without many of these details. Additionally, some well-known structures or functions may not be shown or described in detail so as to avoid unnecessarily obscuring the relevant description of the various embodiments.

The terminology used in the description presented below is intended to be interpreted in its broadest reasonable manner, even though it is being used in conjunction with a detailed description of certain specific embodiments of the invention. Certain terms may even be emphasized below; however, any terminology intended to be interpreted in any restricted manner will be overtly and specifically defined as such in this detailed description section.

Where the context permits, singular or plural terms may also include the plural or singular term, respectively. Moreover, unless the word “or” is expressly limited to mean only a single item exclusive from the other items in a list of two or more items, then the use of “or” in such a list is to be interpreted as including (a) any single item in the list, (b) all of the items in the list, or (c) any combination of items in the list.

Turning now in detail to the drawings, as shown inFIGS. 1-4, one embodiment of anadjustable hockey helmet10 includes afront shell12 and arear shell14. As shown inFIG. 2, the front andrear shells12,14 include liners ofprotective padding15 screwed, adhered, or otherwise affixed to interior surfaces of theshells12,14. Thepadding15 may be made of a foam material, such as expanded polypropylene (“EPP”), or of any other material or combination of materials suitable for protecting a wearer's head.

Thefront shell12 includes twoside plates16, which are preferably positioned in recesses in thefront shell12. As is best shown inFIG. 5, two rivets18, or other suitable connectors, are insert-molded within (or otherwise affixed to) an inner surface of each of theside plates16. The rivets18 are preferably made of a metal material, such as aluminum, but may be made of any other suitable material. Any other suitable number of rivets18 may alternatively be used.

The rivets18 extend through aligned slots oropenings17 in the front andrear shells12,14. The rivets18 are preferably press-fit intofemale receiving elements22, which are molded onto or otherwise affixed to substantially rigid side straps24, shown inFIG. 6, positioned inside thehelmet10. This press-fit relationship, shown inFIG. 7, provides an appropriate tolerance between eachside plate16 and itscorresponding side strap24 to allow theshells12,14 (omitted fromFIG. 7 for clarity) to be longitudinally adjusted with respect to each other.

As shown inFIG. 3, the side straps24 extend into the rear interior of thehelmet10. In one embodiment, anupper strap26, which is ultrasonically welded or otherwise attached to an upper exterior region of thefront shell12, also extends into the rear interior of thehelmet10. Theupper strap26 is optionally attached to thefront shell12 at a location underneath a front region of therear shell14. The side straps24 and theupper strap26 may be made of nylon or polyethylene, or of any other material or combination of materials having enough strength or stiffness to prevent longitudinal adjustment of the front andrear shells12,14 when thestraps24,26 are held securely in place inside thehelmet10, as further described below. While twoside straps24 and oneupper strap26 are shown, any other suitable number of straps may be used in thehelmet10. For example, in one embodiment, theupper strap26 may be omitted such that only the side straps24 are included.

As shown inFIG. 3, in one embodiment, one or more upper strap sleeves or strap guides30 are attached to an upper interior surface of therear shell14 for guiding theupper strap26 and maintaining it in a position close to the upper interior surface. Theupper strap26 passes through theupper strap guide30 toward the rear interior of thehelmet10. Similarly, one or more side strap sleeves or strap guides32 may be attached to each inner side surface of therear shell14 for guiding each of the side straps24 and maintaining them close to the inner side surfaces. Eachside strap24 passes through its correspondingside strap guide32 toward the rear interior of thehelmet10. In an alternative embodiment, a lesser or greater number of strap guides may be included, or strap guides may be omitted altogether.

As shown inFIGS. 4 and 8-10, acam assembly35 is included at a rear region of therear shell14. Thecam assembly35 includes an exterior cam handle36 attached to acam post38. Thecam post38 extends through an opening in therear shell14 into the interior of thehelmet10. Acam plate40 is attached to an end of thecam post38 via anut41 or other suitable connector. Alternatively, thecam plate40 may be molded or otherwise affixed to thenut41. A connector with male threads, and a receptor with female threads, may alternatively be used in place of thenut41 andcam post38, respectively.

Theupper strap26 and the side straps24 optionally each include a slot or opening28 near their free ends. Theopenings28 in each of thestraps24,26 are positioned around thecam post38 such that the ends of thestraps24,26 partially overlap one another. A reinforcing plate orshim42 is optionally positioned around thecam post38 between thestraps24,26 and the interior surface of therear shell14 to provide a clamping surface for thestraps24,26, as well as structural support for thecam assembly35. In one embodiment, theshim42 is positioned within a recess in the interior surface of therear shell14. Theshim42 prevents transmission of excessive compressive force against the interior surface of therear shell14, and thus inhibits or prevents permanent compression or “creep” in therear shell14. If creep does occur, thenut41 may be tightened to compensate for the creep.

The cam handle36 is preferably rotatable between an open position in which the cam handle36 is in a substantially horizontal position extending away from an outer surface of therear shell14, as shown inFIG. 4B, and a closed position in which the cam handle36 is in a substantially vertical position against or adjacent to the outer surface of therear shell14, as shown inFIGS. 4A and 8-10. When in the open position, the cam handle36 urges thecam post38 toward the interior of thehelmet10, pushing thecam plate40 away from thestraps24,26 so that they are free to move or slide about thecam post38. When in the closed position, the cam handle36 urges thecam post38 toward the rear of thehelmet10, pulling thecam plate40 against thestraps24,26. In this closed position, thecam plate40 presses thestraps24,26 against the shim42 (or against the interior surface of therear shell14 if theshim42 is omitted) so that they are prevented from moving or sliding about thecam post38.

When thecam assembly35 is in the open position, the length of thehelmet10 may be adjusted by pushing the front andrear shells12,14 toward each other or by pulling them away from each other. During this adjustment, thestraps24,26 are guided via their respective strap guides30,32, while theiropenings28 slide or move about thecam post38. After thehelmet10 is adjusted to a desired length, the cam handle36 may be rotated into the closed position to secure the side straps24 and theupper strap26 against the shim42 (or against the interior surface of therear shell14 if ashim42 is omitted). When in the closed position, the rigidity or stiffness of thestraps24,26 prevents further longitudinal adjustment of thehelmet10.

This single-cam system allows for faster length adjustment than the multi-cam or multi-screw systems used in many existing helmets. Furthermore, a snug fit can more readily be achieved when thehelmet10 is positioned on a wearer's head, since the wearer can use one hand to adjust and hold the helmet in place, while using the other hand to close the cam handle36 to secure thehelmet10 in place.

In an alternative embodiment, single-screw side plates may be used to provide longitudinal helmet adjustment, instead of the strap-based, cam-lock system described above. In this embodiment, each side plate includes one insert-molded rivet on its inner surface, and an opening through which a screw or bolt may be threaded (instead of including a second rivet). In the closed or locked position, the screw or bolt is threaded through the opening in the side plate, through thefront shell12, and into a threaded receiving element in therear shell14. Alternatively, the side plate may be omitted and the screw or bolt may be threaded directly through thefront shell12 into the threaded receiving element in therear shell14.

To adjust the helmet's length, a user loosens or partially unthreads the single screw in each side plate, which allows the front andrear shells12,14 to be longitudinally adjusted relative to each other. Once a desired length is achieved, the user tightens the single screw in each side plate to secure the front andrear shells12,14 to each other, thus preventing longitudinal movement between them. Many existing adjustable helmets, conversely, typically include two screws in each side plate (or in the helmet shells on each side of the helmet), and therefore require more time and effort to perform length adjustments.

In a related embodiment, the single screw may be replaced with a wing-nut, which may be loosened and tightened by hand. The wing-nut may include a folding or pivoting flap, which, when pivoted to the closed position, abuts or is adjacent to the helmet's surface. When the flap is pivoted to the open position, it provides enough surface area for a user to twist the wing-nut and unthread it from the receiving element in therear shell14. Thus, including a wing-nut instead of a standard screw obviates the need for a screwdriver when adjusting the helmet's length.

In one embodiment, as shown inFIGS. 2, 3, 11, and 12, thehelmet10 may additionally or alternatively include a lateral and occipital adjustment system48 configured to engage the sides and back of a wearer's head or the nape of the wearer's neck. The lateral and occipital adjustment system48 includes one ormore bands50 or straps attached or affixed to the padding15 (or to the front shell12) in the front interior region of thehelmet10, via screws, snaps, or any other suitable connectors. Thebands50 or straps are preferably made of a relatively flexible plastic, nylon, or other suitable material.

Thebands50 or straps may be tightened or loosened, such that they are displaced laterally toward or away from the central interior of thehelmet10, via a dial in adial housing52, a knob, or another device located at a rear of thehelmet10. The lateral and occipital adjustment system48 also preferably includes anupper attachment portion53 that may be attached to theliner padding15, or to therear shell14, or to a separate attachment element55 (seeFIG. 2), via screws, snaps, or any other suitable connectors. Anoccipital pad57 or similar element is preferably attached to thedial52, thestraps50, or theattachment portion53 for engaging the rear of a wearer's head or the nape of the wearer's neck. Any other suitable lateral and occipital adjustment system may alternatively be used in thehelmet10.

Theadjustable helmet10 may include one or more of the longitudinal, lateral, and occipital adjustment systems described above.FIG. 12 shows the general spatial relationship between the longitudinal, lateral, and occipital adjustment systems when all are included in ahelmet10, according to one embodiment. Variations may of course be made to the relative spacing and orientation of the various adjustment systems.

In an alternative embodiment, the various adjustment systems may be integrated with one another. For example, the longitudinal and lateral adjustment systems may be operable via a single knob and cam system. In such a system, the knob may first be rotated to adjust the longitudinal length of the front andrear shells12,14. The cam mechanism may then be moved into the locked position, after which the knob may be turned to adjust the lateral bands of the system. The reverse of this system, in which the lateral bands are adjusted when the cam is in the unlocked position, may alternatively be used. These integrated adjustment systems may be accomplished using gears associated with the cam system or using another suitable switching mechanism.

One or more of the following additional features may optionally be included in theadjustable helmet10. As shown inFIGS. 1 and 13, height-adjustable earpieces54 may be included to allow a wearer to adjust the vertical position of theearpieces54 on thehelmet10. Anopening56 in each earpiece is preferably positioned over a raised projection (not visible in the drawings) on an interior surface of thefront shell12. A clamping plate59 or similar structure, which may be a molded foam or similar material, includes threaded receivingelements61 or other receiving elements. The clamping plate59 is positioned behind (i.e., toward the interior of the helmet10) theearpiece54 to provide a clamping force on theearpiece54 when one or more screws or other suitable connectors are threaded into the receivingelements61.

The rear region of theearpiece54 is sandwiched between the inner surface of therear shell14 and theliner padding15. The rear region of theearpiece54 includes aslot58 or opening that is positioned around a post-screw assembly (not visible in the drawings) used to attach theliner padding15 to therear shell14. The post-screw assembly provides a point of rotation for theearpiece54. To adjust the height of theearpiece54, a user loosens the screws in the receivingelements61, causing the clamping plate to release its clamping force on theearpiece54. The user then rotates the front region of theearpiece54 to a desired height, after which the user tightens the screws to secure theearpiece54 at the desired height. The raised projection positioned in theopening56 limits the vertical movement of theearpiece54 in the upward and downward directions by engaging the upper or lower surfaces that define the upper and lower regions of theopening56.

As shown inFIGS. 1 and 14, height-adjustable J-clips60 may optionally be included at the temple regions of thefront shell12. Each J-clip60 includes ahooded arm62 or similar device for preventing an optional face protector from over-rotating into a wearer's face during impact with a puck or other object. The J-clip includes aslot64 about which four substantially circular regions, which are defined byridges65, are longitudinally arranged for receiving twoscrews66 or similar connectors (or any other suitable number of screws or connectors) that are threaded into openings in thefront shell12. A user may adjust the vertical height of the J-clip60 relative to thefront shell12 by partially loosening thescrews66 until the heads of thescrews66 move beyond theridges65. The user then slides the J-clip60 into the desired vertical position, after which the user re-tightens thescrews66.

A conventional J-clip, conversely, includes four round holes into which two screws may be threaded, allowing the J-clip to be moved between the high and low positions. To move a conventional J-clip between these two positions, however, the two screws must be completely removed from the helmet shell, then re-inserted and re-tightened once the J-clip's position has been adjusted. Thus, the slotted configuration shown inFIGS. 1 and 14 allows for more efficient adjustment of the J-clip60.

In an alternative embodiment, the recessed slot may include longitudinal ridges instead ofridges65 that define substantially circular regions. In such an embodiment, thescrews66 must be adequately tightened to prevent vertical movement of the J-clip60 without the aid of the circular regions. In another alternative embodiment, a horizontal divider, which divides theslot64 into two separate vertical slotted regions, may be included to provide additional strength to the J-clip60.

As shown inFIGS. 1 and 15, ear-loops70 are preferably attached to the front andrear shells12,14 on each side of thehelmet10. The ear-loops70 include enlarged end portions71 that are insertable through slots or openings in the front andrear shells12,14 for securing the ear-loops70 to thehelmet10. The rear portion (or front portion) of each ear-loop70 includes a raisedledge72, bead, or similar feature that snaps into or squeezes through the slot in the rear shell14 (or the front shell12) when the ear-loop70 is rotated into an up position, thus maintaining the ear-loop70 in an up position. Players often like to flip up their ear-loops during warm-ups and in between periods. Conventional ear-loops, however, typically do not remain in the up position because they do not include a mechanism for maintaining the ear-loop in the up position.

As shown inFIGS. 1 and 16, afront plate74, which may be made of a nylon material or other similar material, includes a plurality ofposts76 injection-molded or otherwise integrated onto its rear surface. The front-facing region of thefront shell12 includes a recessed area including corresponding openings into which theposts76 may be inserted. Theposts76 are optionally heat-staked into the openings to permanently attach them to thefront shell12. A bubble logo or other decorative element may be adhered or otherwise affixed to the front surface of thefront plate74. Because the front surface of thefront plate74 is made of a nylon or similar material, as opposed to polyethylene, the logo or decorative element can be securely glued to thefront plate74.

As shown inFIGS. 1 and 17A, a front screw-plate80 may be included for securing thefront shell12 to theliner padding15. The screw-plate80 includes two circular, threaded receivingelements82 molded on or otherwise integrated thereon. Thefront shell12 includes two circular openings in which the receivingelements82 are positioned.

The screw-plate80 is directly or indirectly affixed to a portion of thefront liner padding15. In one embodiment, a stiff fabric material is sandwiched between the screw plate80 and the interior surface of thefront shell12. The stiff fabric material has a greater surface area than, and therefore extends beyond the boundaries of, the screw plate80. Theliner padding15 may be adhered or otherwise affixed to the stiff fabric material.Screws78 or bolts are threaded from the exterior of thefront shell12 into the receivingelements82 to secure the fabric material between thefront shell12 and the screw-plate80.

FIG. 17B illustrates an alternative embodiment of ascrew plate81 includinglateral flanges83 positioned adjacent to two circular, threaded receivingelements85. Thescrew plate81 may be a unitary piece or may include one or more support arms, such as theupper support arm87 and thelower support arm89 shown inFIG. 17B. Thescrew plate81 is preferably embedded within a front region of theliner padding15. The receivingelements85 protrude out of theliner padding15 and are positioned in the circular openings in thefront shell12 for receiving thescrews78 or bolts.

During threading of thescrews78 or bolts, the receivingelements82 or85 are prevented from rotating due to their connection via the screw-plate80 or81 in conjunction with their positioning in the shell openings. Many existing helmets, conversely, use individual, non-circular receiving elements that fit into non-circular holes in the helmet shell. The receiving elements are non-circular to prevent them from rotating within the shell openings when screws or bolts are threaded into the non-circular receiving elements. Thus, by incorporating a single, integrated screw-plate80 or81,circular receiving elements82 or85 may be used to secure thefront shell12 to theliner padding15.

As shown inFIG. 18, achin strap84, which may be attached at its free ends to the ear-loops70 or to other suitable helmet regions, includes amagnetic buckle86. Thebuckle86 includes afirst component88 and asecond component90, each including amagnet92 insert-molded thereon or otherwise affixed thereto.

The first andsecond components88,90 preferably include first andsecond walls94,96, respectively, each oriented substantially perpendicularly to the face onto which itsrespective magnet92 is molded. The first andsecond walls94,96 engage each other when the first andsecond components88,90 are magnetically coupled to each other. This wall arrangement prevents the first and second88,90 components from readily disengaging from each other when the chin-strap is pulled in tension. The first andsecond walls94,96, in conjunction with themagnets92, are optionally configured in a manner that allows the first andsecond components88,90 to disengage from each other when a predetermined amount of tensile force is applied to thechin strap84. Themagnetic buckle86 is substantially easier to connect and disconnect than are traditional snap-fit arrangements.

As shown inFIG. 19, a chin-cup assembly98 for use on an optionalwire cage facemask102 includes achin cup100 and achin cup retainer104. Thechin cup100 may be injection-molded, compression-molded, or otherwise formed, and optionally includes female receivingelements106 molded therein. Theretainer104 optionally includes corresponding insert-molded male snaps108 or rivets (the male and female elements could of course be reversed). Thechin cup100 and theretainer104 may be press-fit together or otherwise attached to each other around the wires of thefacemask102.

An integral, vertically extendingindexing arm110 is optionally included on theretainer104. Theindexing arm110 includeshorizontal grooves112 that can snap over the horizontal wires on thefacemask102. To adjust the height of thechin cup100, a user slides thechin cup assembly98 to a desired height on thefacemask102, allowing a wire to snap into one of thehorizontal grooves112. Thus, thechin cup assembly98 can be secured in a desired location, and does not have to be removed from thefacemask102 to have its vertical position adjusted on thefacemask102.

As shown inFIG. 20, a substantially rear-projectingtab120 or similar element may be included on the interior surface of therear shell14 for engaging acorresponding slot122 in theliner padding15. Thetab120 substantially prevents thepadding15 from rotating in a forward direction, which is often an issue with existing helmets. In an alternative embodiment, thetab120 may be included on theupper strap guide30, which is secured to the upper interior surface of therear shell14.

As shown inFIG. 21, acomfort pad130 made of a soft foam or other soft material may be included at the front of thehelmet10 to provide a soft engagement surface, when the helmet is rotated forward, for a wearer's nose. A channel is optionally created in the lower front edge of theliner padding15 for receiving thecomfort pad130, which may be adhered or otherwise affixed to the liner padding or to thefront shell12.

As shown inFIGS. 22 and 23, a head-form140 may be included as part of the helmet's packaging. The head-form140 may be made of expanded polystyrene (EPS) or of another suitable material. The head-form140 preferably includes abase region144 configured to fit within apackaging box146. Thebase region144 preferably includesside openings148 to accommodate the ear-loops70 and thechin strap84 of thehelmet10.

The head-form140 substantially fills the interior of thehelmet10 and substantially prevents the liner padding15 from being dented or damaged during shipping and handling. The liner padding in many existing helmets, conversely, often becomes marked or dented because the padding is exposed during shipping and while the helmet rests on a shelf.

The head-form140 preferably includes aslot142 or opening in its rear upper region, or in another suitable location. Theslot142 provides flexibility so that the head-form140 may accommodate different helmet sizes. For example, when a medium helmet is placed over the head-form140, the sides of the head-form140 are pressed toward each other such that theslot142 is narrowed. When a small helmet is placed over the head-form140, the sides of the head-form140 are pressed toward each other to a greater degree such that theslot142 is narrowed even further. Accordingly, the head-form140 may be snugly secured within helmets of various sizes.

The various helmet components described herein, if not otherwise specified, may be made of any suitable material or combination of materials. While specific elements are often described above, in many cases, other suitable elements may be used in their place (e.g., wing-nuts may be used instead of screws, where applicable).

Any of the above-described embodiments may be used alone or in combination with one another. Furthermore, the adjustable helmet may include additional features not described herein. While several embodiments have been shown and described, various changes and substitutions may of course be made, without departing from the spirit and scope of the invention. The invention, therefore, should not be limited, except by the following claims and their equivalents.

Claims (57)

What is claimed is:

1. An adjustable helmet, comprising:

a first shell;

padding attached to the first shell;

a second shell engaged with the first shell;

a plurality of substantially rigid straps connected to the first shell and extending into the second shell;

a cam assembly on the second shell in engagement with the straps, wherein the straps are movable relative to the cam assembly, and the cam assembly includes a cam handle that is pivotable between:

an open position in which the straps are free to move through the cam assembly, such that the first shell may be longitudinally adjusted relative to the second shell; and

a closed position in which the straps are prevented from moving through the cam assembly, such that the first shell is prevented from being longitudinally adjusted relative to the second shell.

2. The helmet ofclaim 1 wherein the first shell is a front shell and the second shell is a rear shell, or the first shell is a rear shell and the second shell is a front shell.

3. The helmet ofclaim 1 further comprising a lateral adjustment mechanism including a plurality of bands attached directly or indirectly to the first shell or the second shell, wherein the bands are configured to engage sides of a wearer's head.

4. The helmet ofclaim 3 wherein the lateral adjustment mechanism further includes a device for tightening and loosening the bands.

5. The helmet ofclaim 3 further comprising a pad attached to the lateral adjustment mechanism for engaging an occipital portion of a wearer's head.

6. The helmet ofclaim 1 further comprising a height-adjustable earpiece on the helmet.

7. The helmet ofclaim 1 further comprising a height-adjustable J-clip attached to the first shell via at least one threaded connector, with the J-clip including a slot positioned around the threaded connector for allowing the J-clip to be vertically adjusted relative to the first shell when the threaded connector is loosened without requiring removal of the threaded connector from the first shell.

8. The helmet ofclaim 1 further comprising an ear loop including a raised ledge configured to pass through a slot in the helmet and to engage an inner surface of the helmet to maintain the ear loop in an upward position.

9. The helmet ofclaim 1 further comprising padding in an interior of the second shell, and a rear-projecting tab on an interior surface of the second shell that engages a slot in the padding to prevent rotation of the padding.

10. An adjustable helmet, comprising:

a first shell;

a second shell engaged with the first shell;

a plurality of substantially rigid straps connected to the first shell and extending into an interior region of the second shell, with each of the straps including an opening;

a cam assembly attached to an exterior region of the second shell, the cam assembly including a cam post extending into the interior region of the second shell and through the openings in the straps, and a cam plate on the cam post;

wherein the cam assembly is movable between:

a closed position in which the cam plate secures the straps against the second shell, such that the first shell is prevented from being longitudinally adjusted relative to the second shell, and

an open position in which the straps are free to move about the cam post such that the first shell may be longitudinally adjusted relative to the second shell.

11. The helmet ofclaim 10 wherein the first shell is a front shell and the second shell is a rear shell, or the first shell is a rear shell and the second shell is a front shell.

12. An adjustable helmet, comprising:

a first shell;

padding attached to the first shell;

a second shell engaged with the first shell;

a plurality of substantially rigid straps connected to the first shell and extending into the second shell;

a cam assembly on an exterior region of the second shell in engagement with the plurality of straps, wherein the cam assembly is not engageable with the first shell.

13. An adjustable helmet, comprising:

a front shell;

padding attached to the front shell;

a rear shell engaged with the front shell;

at least one substantially rigid strap attached to the front shell and extending into the rear shell; and

a cam assembly on an exterior region of the rear shell that is engageable with the strap, wherein the cam assembly includes a cam handle that is pivotable between an open position and a closed position.

14. The helmet ofclaim 13 wherein the strap is attached to an upper region of the front shell such that, in use, the strap overlies the top of a wearer's head.

15. The helmet ofclaim 13 wherein engagement of the cam assembly with the strap substantially prevents longitudinal adjustment of the front shell relative to the rear shell.

16. The helmet ofclaim 13 wherein the cam assembly is located on a rear-exterior region of the rear shell.

17. The helmet ofclaim 13 wherein the strap comprises at least one opening engageable by the cam assembly.

18. An adjustable helmet, comprising:

a first shell;

padding attached to the first shell;

a second shell engaged with the first shell;

at least one substantially rigid strap attached to the first shell and extending into the second shell, wherein the strap is contained within the interior of the helmet; and

means for engaging the strap to substantially prevent longitudinal movement of the first shell relative to the second shell, wherein the means for engaging is located on a rear exterior region of the second shell.

19. An adjustable helmet, comprising:

a) an external protective shell circumscribing an inside region for receiving a wearer's head, the inside region having a longitudinal dimension;

b) a fit adjustment system configured to vary the longitudinal dimension of the inside region and adjust the fit of the helmet on the wearer's head, the fit adjustment system comprising:

i) a first elongated member extending along a first side region of the adjustable helmet;

ii) a second elongated member, generally opposite the first elongated member extending along a second side region of the adjustable helmet;

iii) a manually operable mechanism configured to secure the adjustable helmet in a selected longitudinal dimension of the inside region;

iv) each of the first and the second elongated members including:

a front connection area at which the elongated member connects to the adjustable helmet;

a rear connection area at which the elongated member connects to the manually operable mechanism, whereby movement of the first and the second elongated members with relation to the manually operable mechanism allows varying the longitudinal dimension of the inside region;

v) a first elongated member guide associated with the first elongated member, the first elongated member guide being connected to the helmet independently of the manually operable mechanism and located within the inside region of the helmet between the front connection area and the rear connection area of the first elongated member, the first elongated member guide receiving and supporting the first elongated member and allowing the first elongated member to move relative the first elongated member guide as the longitudinal dimension is varied;

vi) a second elongated member guide associated with the second elongated member, the second elongated member guide being connected to the helmet independently of the manually operable mechanism and located within the inside region of the helmet between the front connection area and the rear connection area of the second elongated member, the second elongated member guide receiving and supporting the second elongated member and allowing the second elongated member to move relative the second elongated member guide as the longitudinal dimension is varied.

20. The adjustable helmet as defined in claim 19, wherein the first and the second elongated members are mounted along an internal surface of the helmet.

21. The adjustable helmet as defined in claim 20, wherein the internal surface of the helmet is generally concave, the first and the second elongated members have a curved configuration conforming to the generally concave internal surface.

22. The adjustable helmet as defined in claim 20, wherein the first and the second elongated member guides project from the internal surface.

23. The adjustable helmet as defined in claim 19, wherein the first and the second elongated members are formed, at least in part, from nylon.

24. The adjustable helmet as defined in claim 19, wherein the first and the second elongated members are formed, at least in part, from polyethylene.

25. The adjustable helmet as defined in claim 19, wherein each of the first and the second elongated member guides comprises a member extending in a direction generally transverse to the elongated dimension of its associated elongated member.

26. The adjustable helmet as defined in claim 19, wherein the front connection areas of the first and the second elongated members are located at temple regions on the first and the second side regions of the adjustable helmet.

27. The adjustable helmet as defined in claim 19, wherein the front connection area of each of the first and the second elongated members includes at least one projection for connection of the elongated member to the adjustable helmet.

28. The adjustable helmet as defined in claim 19, further comprising interior padding in an interior of the exterior protective shell, the interior padding comprising:

liner padding attached to the exterior protective shell; and

comfort padding arranged to contact the wearer's head when the helmet is worn.

29. The adjustable helmet as defined in claim 28, wherein each of the first and the second elongated member guides is at least partially covered by a portion of the comfort padding that is located between the elongated member guide and the wearer's head when the helmet is worn.

30. The adjustable helmet as defined in claim 28, wherein the comfort padding comprises a plurality of comfort pads arranged to contact different portions of the wearer's head when the adjustable helmet is worn.

31. The adjustable helmet as defined in claim 30, wherein the plurality of comfort pads comprises:

a first comfort pad disposed between the first elongated member guide and the wearer's head and when the helmet is worn; and

a second comfort pad disposed between the second elongated member guide and the wearer's head when the helmet is worn.

32. The adjustable helmet as defined in claim 31, wherein the plurality of comfort pads further comprises an occipital pad configured to engage an occipital region of the wearer's head.

33. The adjustable helmet as defined in claim 32, wherein the occipital pad is mounted to an attachment portion that extends upwardly therefrom to connect the occipital pad to a portion of the helmet that is located above the occipital pad.

34. The adjustable helmet as defined in claim 19, wherein the manually operable mechanism is the sole actuator to perform an adjustment of the longitudinal dimension of the inside region to adjust a fit of the adjustable helmet.

35. A fit adjustment system for adjusting the fit of a helmet having an external protective shell circumscribing an inside region for receiving a wearer's head, the fit adjustment system comprising:

i) a first elongated member configured such that, when the fit adjustment system is installed in the helmet, the first elongated member extends along a first side region of the helmet;

ii) a second elongated member configured such that, when the fit adjustment system is installed in the helmet, the second elongated member extends along a second side region of the helmet generally opposite the first elongated member;

iii) a manually operable mechanism configured to secure the helmet in a selected longitudinal dimension of the inside region;

iv) each of the first and the second elongated members including:

a front connection area for connecting the elongated member to the adjustable helmet;

a rear connection area for connecting the elongated member to the manually operable mechanism, whereby movement of the first and the second elongated members with relation to the manually operable mechanism allows varying the longitudinal dimension of the inside region;

v) a first elongated member guide associated with the first elongated member and configured such that, when the fit adjustment system is installed in the helmet, the first elongated member guide is connected to the helmet independently of the manually operable mechanism and located within the inside region of the helmet between the front connection area and the rear connection area of the first elongated member, the first elongated member guide receiving and supporting the first elongated member and allowing the first elongated member to move relative the first elongated member guide as the longitudinal dimension is varied;

vi) a second elongated member guide associated with the second elongated member and configured such that, when the fit adjustment system is installed in the helmet, the second elongated member guide is connected to the helmet independently of the manually operable mechanism and located within the inside region of the helmet between the front connection area and the rear connection area of the second elongated member, the second elongated member guide receiving and supporting the second elongated member and allowing the second elongated member to move relative the second elongated member guide as the longitudinal dimension is varied.

36. The fit adjustment system as defined in claim 35, wherein, when the fit adjustment system is installed in the helmet, the first and the second elongated members are mounted along an internal surface of the helmet.

37. The fit adjustment system as defined in claim 36, wherein the first and the second elongated member guides project from the internal surface.

38. The fit adjustment system as defined in claim 36, wherein the first and the second elongated members are formed, at least in part, from nylon.

39. The fit adjustment system as defined in claim 35, wherein each of the first and the second elongated member guides comprises a member extending in a direction generally transverse to the elongated dimension of its associated elongated member.

40. The fit adjustment system as defined in claim 35, wherein the first and the second elongated members are configured such that, when the fit adjustment system is installed in the helmet, the front connection areas of the first and the second elongated members are located at temple regions on the first and the second side regions of the helmet.

41. The fit adjustment system as defined in claim 35, wherein the front connection area of each of the first and the second elongated members includes at least one projection for connection of the elongated member to the helmet.

42. The fit adjustment system as defined in claim 35, further comprising comfort padding arranged to contact a wearer's head when the helmet is worn, wherein each of the first and the second elongated member guides is at least partially covered by a portion of the comfort padding that is located between the elongated member guide and the wearer's head when the fit adjustment system is installed in the helmet and the helmet is worn.

43. An adjustable helmet, comprising:

a) an external protective shell circumscribing an inside region for receiving a wearer's head, the inside region having a longitudinal dimension;

b) a fit adjustment system configured to vary the longitudinal dimension of the inside region and adjust the fit of the helmet on the wearer's head, the fit adjustment system comprising:

i) an elongated member extending along an internal surface of the helmet;

ii) a manually operable mechanism configured to secure the adjustable helmet in a selected longitudinal dimension of the inside region;

iii) the elongated member including:

a front connection area at which the elongated member connects to the adjustable helmet;

a rear connection area at which the elongated member connects to the manually operable mechanism, whereby movement of the elongated member with relation to the manually operable mechanism allows varying the longitudinal dimension of the inside region;

iv) an elongated member guide associated with the elongated member, the elongated member guide being connected to the helmet independently of the manually operable mechanism and located within the inside region of the helmet between the front connection area and the rear connection area of the elongated member, the elongated member guide receiving and supporting the elongated member and allowing the elongated member to move relative the elongated member guide as the longitudinal dimension is varied;

v) interior padding residing between the protective shell and the head of the wearer when the helmet is being worn, the interior padding including a recess into which a portion of the elongated member guide is received.

44. The adjustable helmet as defined in claim 43 wherein the internal surface of the helmet is generally concave, the elongated member having a curved configuration conforming to the generally concave internal surface.

45. The adjustable helmet as defined in claim 43, wherein the elongated member guide projects from the internal surface.

46. The adjustable helmet as defined in claim 43, wherein the elongated member is formed, at least in part, from nylon.

47. The adjustable helmet as defined in claim 43, wherein the elongated member guide comprises a member extending in a direction generally transverse to the elongated dimension of the elongated member.

48. The adjustable helmet as defined in claim 43, wherein the front connection area of the elongated member includes at least one projection for connection of the elongated member to the adjustable helmet.

49. The adjustable helmet as defined in claim 43, wherein the interior padding comprises:

liner padding attached to the exterior protective shell; and

comfort padding arranged to contact the wearer's head when the helmet is worn.

50. The adjustable helmet as defined in claim 49, wherein the recess into which a portion of the elongated member guide is received is a recess defined in the liner padding.

51. The adjustable helmet as defined in claim 49, wherein the elongated member guide is at least partially covered by a portion of the comfort padding that is located between the elongated member guide and the wearer's head when the helmet is worn.

52. The adjustable helmet as defined in claim 51, wherein the comfort padding comprises a plurality of comfort pads arranged to contact different portions of the wearer's head when the adjustable helmet is worn.

53. The adjustable helmet as defined in claim 52, wherein the comfort padding comprises an occipital pad configured to engage an occipital region of the wearer's head.

54. The adjustable helmet as defined in claim 53, wherein the occipital pad is mounted to an attachment portion that extends upwardly therefrom to connect the occipital pad to a portion of the helmet that is located above the occipital pad.

55. The adjustable helmet as defined in claim 49, wherein the elongated member and the associated elongated member guide are a first elongated member and a first elongated member guide, the fit adjustment system further comprising:

vi) a second elongated member extending along an inner surface of the adjustable helmet;

vii) the second elongated member including:

a front connection area at which the second elongated member connects to the adjustable helmet;

a rear connection area at which the second elongated member connects to the manually operable mechanism, whereby movement of the first and the second elongated members with relation to the manually operable mechanism allows varying the longitudinal dimension of the inside region;

viii) a second elongated member guide associated with the second elongated member, the second elongated member guide being connected to the helmet independently of the manually operable mechanism and located within the inside region of the helmet between the front connection area and the rear connection area of the second elongated member, the second elongated member guide receiving and supporting the second elongated member and allowing the second elongated member to move relative the second elongated member guide as the longitudinal dimension is varied.

56. The adjustable helmet as defined in claim 55, wherein the comfort padding comprises:

a first comfort pad disposed between the first elongated member guide and the wearer's head and when the helmet is worn; and

a second comfort pad disposed between the second elongated member guide and the wearer's head when the helmet is worn.

57. The adjustable helmet as defined in claim 43, wherein the manually operable mechanism is the sole actuator to perform an adjustment of the longitudinal dimension of the inside region to adjust a fit of the adjustable helmet.

Images