Helmet impact liner system

CROSS REFERENCE TO RELATED APPLICATION

p-0002This application is a U.S. Non-Provisional patent application which claims priority to U.S. Provisional Patent Application No. 61/503,822, filed on Jul. 1, 2011 and titled “Helmet Impact Liner System,” which is hereby incorporated by reference in its entirety.

BACKGROUND

p-0003Helmets, such as sporting helmets, generally include a shell and a liner. The helmet shell generally provides protection from protruding objects and is often configured to spread the impact load across the footprint of the helmet. The helmet liner is generally made of a softer and lower density material than the helmet shell. The helmet liner is often configured such that, upon impact, the helmet liner at least partially absorbs the impact energy from the force of an impact.

SUMMARY

p-0004The present application discloses a helmet, an impact liner system for a helmet, an air channel insert for an impact liner, and an impact liner kit for a helmet.

p-0005For example, in one embodiment, a helmet comprising a helmet shell and an impact liner is disclosed. The impact liner is configured to be installed in the interior of the helmet shell to at least partially line the front, rear, and middle portions of the helmet shell. The impact liner comprises a front impact pad array, a middle impact pad array, and a rear impact pad array. Each impact pad array comprises a plurality of impact pads. The impact liner forms a plurality of air channels between the impact pads of the impact pad arrays when the impact liner is installed in the helmet shell. In certain embodiments, at least one insert is disposed within one or more of the plurality of air channels. The insert generally comprises a body portion having a top and vertical side walls configured to prohibit at least a portion of the air channel from collapsing when the helmet shell is installed on a user's head. Further, the helmet may include a plurality of comfort pads removably attached to the impact liner.

p-0006In another embodiment, an impact liner system is disclosed. The impact liner system comprises an impact liner configured to be installed in the interior of a helmet shell to at least partially line the front, rear, and middle portions of the helmet shell. The impact liner comprises a plurality of impact pads and forms a plurality of air channels between the impact pads when the impact liner is installed in the helmet shell. In certain embodiments, at least one insert is disposed within one or more of the plurality of air channels. The insert generally comprises a body portion having a top and vertical side walls configured to prohibit at least a portion of the air channel from collapsing when the helmet shell is installed on a user's head. Further, the impact liner system may include a plurality of comfort pads configured to be removably attached to the impact liner.

p-0007In yet another embodiment, an impact liner kit for a helmet shell is disclosed. The kit comprises an impact liner and at least one insert. The impact liner is configured to be installed in the interior of a helmet shell and comprises a front impact pad array, a middle impact pad array, and a rear impact pad array. Each impact pad array comprises a plurality of impact pads. The impact liner forms a plurality of air channels between the impact pads of the impact pad arrays when the impact liner is installed in the helmet shell. The at least one insert is configured to be installed within one or more of the plurality of air channels. The insert comprises a body portion having a top and vertical side walls configured to prohibit at least a portion of the air channel from collapsing when the helmet shell is installed on a user's head. In certain embodiments, the kit may include one or more comfort pads configured to be removably attached to the impact liner.

BRIEF DESCRIPTION OF THE DRAWINGS

p-0008<figref idrefs="DRAWINGS">FIGS. 1A and 1B</figref> are perspective and top plan views, respectively, of an impact liner according to an embodiment of the present application.

p-0009<figref idrefs="DRAWINGS">FIG. 2A</figref> is a top plan view of an impact liner in a folded configuration to be installed in a helmet shell according to an embodiment of the present application.

p-0010<figref idrefs="DRAWINGS">FIGS. 2B and 2C</figref> are perspective views of the impact liner of <figref idrefs="DRAWINGS">FIG. 2A</figref> installed in a helmet shell according to an embodiment of the present application.

p-0011<figref idrefs="DRAWINGS">FIGS. 3A and 3B</figref> are perspective and side elevation views, respectively, of an air channel insert according to an embodiment of the present application.

p-0012<figref idrefs="DRAWINGS">FIGS. 3C and 3D</figref> are perspective and side elevation views, respectively, of an air channel insert according to an embodiment of the present application.

p-0013<figref idrefs="DRAWINGS">FIG. 4</figref> is a partial bottom plan view of an impact liner and air channel inserts according to an embodiment of the present application.

p-0014<figref idrefs="DRAWINGS">FIG. 5</figref> is a top plan view of comfort pads and air channel inserts according to an embodiment of the present application.

p-0015<figref idrefs="DRAWINGS">FIG. 6</figref> is a top plan view of an impact liner system installed in a helmet shell according to an embodiment of the present application.

p-0016<figref idrefs="DRAWINGS">FIG. 7</figref> is a top plan view of an impact liner system installed in a helmet shell according to an embodiment of the present application.

p-0017While the drawings herein are to relative scale, it is within the disclosure of this specification to vary the relative size of components to one another.

DESCRIPTION OF EMBODIMENTS

p-0018The present application discloses a helmet, an impact liner system for a helmet, an air channel insert for an impact liner, and an impact liner kit for a helmet. In the embodiments disclosed herein, the impact liner system of the present application is described for use with a helmet configured to protect the head of the user. Exemplary helmets may include, but are not limited to, military helmets, sporting helmets, such as football, lacrosse, hockey, multi-sport, cycling, softball, or baseball helmets, or safety helmets, such as industrial or construction helmets.

p-0019The impact liner system of the present application is configured to attach to the interior of the helmet shell and may be positioned between the user's head and the helmet shell. The impact liner system comprises one or more pads that absorb and/or dissipate the impact energy from the force of an impact. The one or more pads may deform or crush upon impact and consume a portion of the impact energy such that it does not reach the user's head. The one or more pads may also dissipate the impact force over a larger surface area than the actual area of impact so that the force per unit area is decreased for the head compared to that for the initial impact surface (e.g., the outer surface of the helmet shell).

p-0020The impact liner system generally comprises an impact liner configured to line the front, rear, and middle portions of the interior of a helmet. The impact liner includes one or more impact pads and air channels for routing external air between the impact pads. Further, the impact liner system may include one or more inserts positioned in the one or more air channels. The impact liner system may also include one or more comfort pads attached to the impact liner, such as, for example, at the front and rear portions of the impact liner.

p-0021<figref idrefs="DRAWINGS">FIGS. 1A and 1B</figref> illustrates an impact liner <b>100</b> of an impact liner system according to an embodiment of the present application. As illustrated, the impact liner <b>100</b> includes an array of front impact pads <b>102</b>, middle impact pads <b>104</b>, and rear impact pads <b>106</b>. The impact pad arrays may be configured in a variety of sizes and dimensions to accommodate a range of head sizes. Further, the impact pad arrays may be connected together to form a unitary component of impact pads.

p-0022Each impact pad array comprises one or more impact pads encased in a liner material <b>108</b>. The liner material <b>108</b> holds the impact pads in relative position to one another and also attaches the impact pads together. The impact pads and the liner material <b>108</b> are flexible such that the array of impact pads may be formed within the interior of a helmet shell. As such, the impact pad arrays are capable of being folded to substantially conform to the shape of the interior of a helmet shell.

p-0023As illustrated in <figref idrefs="DRAWINGS">FIG. 1B</figref>, each impact pad array is substantially disposed about a centerline C_Lof the impact liner <b>100</b>. As such, in this embodiment, each impact pad array possesses a geometry on one side of the centerline C_Lthat is a mirror image of the geometry on the other side of the centerline C_L.

p-0024In certain embodiments, the impact pads of impact liner <b>100</b> comprise a flexible and resilient polyurethane foam having an average density between about 3.0 and 12.0 lbs/ft³and an average thickness between about 0.325 and 1.0 inch. For example, in one embodiment, the impact pads comprise a polyurethane foam having an average density of about 4.0 lbs/ft³and an average thickness of about 0.5 inches. One example of such a polyurethane foam is Zorbium™ Foam from Team Wendy, LLC. However, the impact pads may comprise a variety of other types of foam or other materials, such as, for example, expanded polypropylene, expanded polystyrene, vinyl nitrile, ethylene-vinyl acetate (EVA), open or closed cell cross linked foams, and molded polymer structures such as thermoplastic urethane (TPU). Further, any one or more of the impact pads may comprise a different type of material than another impact pad. For example, softer and/or thicker impact pads may be positioned toward the front of the helmet shell and more rigid and/or thinner impact pads may be positioned toward the top and/or rear of the helmet shell.

p-0025In certain embodiments, the liner material <b>108</b> comprises a “loop” fabric capable of attaching to the hook portion of a piece of Velcro®. As described below and shown in <figref idrefs="DRAWINGS">FIGS. 6 and 7</figref>, comfort pads may be attached to the impact liner <b>100</b>. The comfort pads may include the hook portion of a piece of Velcro® that attaches to the liner material <b>108</b>. In one embodiment, the liner material <b>108</b> comprises a nylon loop fabric from Guilford Performance Textiles. However, the liner material <b>108</b> may comprise a variety of other types of materials and fabrics. Further, the liner material <b>108</b> may comprise a “hook” fabric capable of attaching to the loop portion of a piece of Velcro®.

p-0026In one embodiment, the liner material <b>108</b> comprises a top portion and bottom portion. The top portion of the liner material is heat sealed to the bottom portion around the impact pads such that the impact pads are held in relative position to one another. Further, as described below, the portions of the liner material between one or more of the impact pads may form a portion of an air channel when the impact pads are installed in a helmet shell.

p-0027As illustrated in <figref idrefs="DRAWINGS">FIGS. 1A and 1B</figref>, the front impact pad array <b>102</b> comprises a first central pad <b>120</b>, a second central pad <b>122</b>, a left pad <b>124</b>, and a right pad <b>126</b>. As shown, the central pads <b>120</b> and <b>122</b> of the front impact pad array <b>102</b> are rectangular in shape. The middle impact pad array <b>104</b> comprises a central pad <b>140</b>, a left pad <b>142</b>, and a right pad <b>144</b>. The rear impact pad array <b>106</b> comprises a first central pad <b>160</b>, a second central pad <b>162</b>, a left rear pad <b>164</b>, a left front pad <b>166</b>, a right rear pad <b>168</b>, and a right front pad <b>170</b>. As shown, the first central pad <b>160</b> of the rear impact pad array <b>106</b> is trapezoidal in shape and the second central pad <b>162</b> is rectangular in shape.

p-0028<figref idrefs="DRAWINGS">FIG. 2A</figref> illustrates the impact liner <b>100</b> of the impact liner system in a folded configuration to be installed in a helmet shell. <figref idrefs="DRAWINGS">FIGS. 2B and 2C</figref> illustrate the impact liner <b>100</b> of the impact liner system installed in a helmet shell <b>200</b>. As shown, the front impact pad array <b>102</b> is installed on the front, sides, and top of the helmet shell <b>200</b>; the middle impact pad array <b>104</b> is installed on the sides and top of the helmet shell; and the rear impact pad array <b>106</b> is installed on the rear, sides, and top of the helmet shell.

p-0029The impact liner <b>100</b> may be installed on the interior of the helmet shell <b>200</b> in a variety of ways, such as, for example, with one or more fasteners, adhesive, clips, pins, snaps, tape, buckles, Velcro®, or a hook and loop. For example, in one embodiment, the impact liner <b>100</b> is installed with one or more pieces of Velcro® to the interior of the helmet shell <b>200</b>. In another embodiment, the liner material <b>108</b> of the impact liner <b>100</b> is attached to the helmet shell <b>200</b> by tabs that are bolted or otherwise attached at a chinstrap mounting point, such as, for example, with a bolt that goes through the helmet shell to attach the chinstrap as well as the impact liner to the helmet shell. In another embodiment, the liner material <b>108</b> of the impact liner <b>100</b> is attached to the helmet shell <b>200</b> with snaps, e.g., snaps attached to the front, rear, and central portions of the impact liner.

p-0030As illustrated in <figref idrefs="DRAWINGS">FIGS. 2B and 2C</figref>, the first central pad <b>120</b> of the front impact pad array <b>102</b> is installed on the front of the helmet shell <b>200</b> and is configured to protect the forehead of the user; the second central pad <b>122</b> is installed on the front top portion of the helmet shell and is configured to protect the front portion of the user's head above the forehead; and the left and right pads <b>124</b> and <b>126</b> are installed on the front left and front right portions of the helmet shell and are configured to protect the front left and front right portions of the user's head.

p-0031As illustrated in <figref idrefs="DRAWINGS">FIGS. 1A and 1B</figref>, the first central pad <b>120</b> of the front impact pad array <b>102</b> comprises a curved edge <b>130</b> that provides added coverage (e.g., relative to a straight edge) when the first central pad is bent around the front interior radius of the helmet shell <b>200</b>. Further, the left and right pads <b>124</b> and <b>126</b> of the front impact array <b>102</b> comprise a first curved edge <b>132</b> that forms a portion of front air channels <b>202</b> when the impact liner <b>100</b> is installed in the helmet shell <b>200</b>. The left and right pads <b>124</b> and <b>126</b> of the front impact array <b>202</b> also comprise a second curved edge <b>138</b> configured such that, when the impact liner <b>100</b> is installed in the helmet shell <b>202</b>, the left and right pads do not cover the ears of the user.

p-0032As illustrated in <figref idrefs="DRAWINGS">FIG. 2A</figref>, the front air channels <b>202</b> are formed between the first curved edge <b>132</b> of the left and right pads <b>124</b> and <b>126</b>, the longitudinal edges <b>134</b> of the central pads <b>120</b> and <b>122</b>, the portion <b>136</b> of the liner material <b>108</b> between the first central pad <b>120</b> and the left and right pads, and the interior of the helmet shell <b>200</b>. Further, the front air channels <b>202</b> have openings <b>220</b> at the front of the helmet shell <b>200</b>. These openings <b>220</b> permit external air A to enter the front air channels <b>202</b> and permit air from inside the helmet shell <b>200</b> to escape to the outside.

p-0033As illustrated in <figref idrefs="DRAWINGS">FIGS. 2B and 2C</figref>, the central pad <b>140</b> of the middle impact pad array <b>104</b> is installed on the middle top portion of the helmet shell <b>200</b> between the second central pads <b>122</b> and <b>162</b> of the front and rear impact pad arrays <b>102</b> and <b>106</b> and is configured to protect the top of the user's head. The left and right pads <b>142</b> and <b>144</b> of the middle impact pad array <b>104</b> are installed on the middle left and middle right portions of the helmet shell <b>200</b> and are configured to protect the left and right portions of the user's head above the ears. The left pad <b>142</b> of the middle impact pad array <b>104</b> is installed between the left pad <b>124</b> of the front impact pad array <b>102</b> and the left front pad <b>166</b> of the rear impact pad array <b>106</b>. The right pad <b>144</b> of the middle impact pad array <b>104</b> is installed between the right pad <b>126</b> of the front impact pad array <b>102</b> and the right front pad <b>170</b> of the rear impact pad array <b>106</b>.

p-0034As illustrated in <figref idrefs="DRAWINGS">FIG. 2A</figref>, the portion <b>150</b> of the liner material <b>108</b> between the central pad <b>140</b> and left and right pads <b>142</b> and <b>144</b> of the middle impact pad array <b>104</b> form a portion of middle air channels <b>204</b> when installed in the helmet shell <b>200</b>. The middle air channels <b>204</b> are formed between edges <b>152</b> of the left and right pads <b>142</b> and <b>144</b>, edges <b>154</b> of the central pad <b>140</b>, the portion <b>150</b> of the liner material <b>108</b> between the central pad and the left and right pads, and the interior of the helmet shell <b>200</b>. The middle air channels <b>204</b> are substantially aligned with the front air channels <b>202</b>. In one embodiment, when the impact liner <b>100</b> is installed in the helmet shell <b>200</b>, the front and middle air channels <b>202</b> and <b>204</b> are substantially parallel to a centerline C_Lof the folded impact liner <b>100</b> (as shown in <figref idrefs="DRAWINGS">FIG. 2A</figref>).

p-0035Further, as illustrated in <figref idrefs="DRAWINGS">FIG. 2A</figref>, when the impact liner <b>100</b> is installed in the helmet shell <b>200</b>, the gap between the pads of the middle impact pad array <b>104</b> and the pads of the front and rear impact pad arrays <b>102</b> and <b>106</b> form transverse air channels <b>206</b> that are substantially perpendicular to the centerline C_Lof the folded impact liner <b>100</b>. As illustrated in <figref idrefs="DRAWINGS">FIG. 2A</figref>, the transverse air channels <b>206</b> are in fluid communication with the front and middle air channels <b>202</b> and <b>204</b>. Further, the transverse air channels <b>206</b> have openings <b>260</b> above the ear portion of the helmet shell <b>200</b>. These openings <b>260</b> permit external air A to enter the transverse air channels <b>206</b> and permit air from inside the helmet shell <b>200</b> to escape to the outside.

p-0036As illustrated in <figref idrefs="DRAWINGS">FIGS. 2B and 2C</figref>, the first central pad <b>160</b> of the rear impact pad array <b>106</b> is installed on the rear of the helmet shell <b>200</b> and is configured to protect the rear of the user's head; the second central pad <b>162</b> is installed on the rear top portion of the helmet shell and is configured to protect the rear top portion of the user's head (e.g., the crown of the head); the left and right rear pads <b>164</b> and <b>168</b> are installed on the rear left and rear right of the helmet shell and are configured to protect the rear left and rear right portions of the user's head; the left front pad <b>166</b> is installed on the left and rear left top portions of the helmet shell and is configured to protect the left and rear left top portions of the user's head (e.g., above and behind the user's left ear); and the right front pad <b>170</b> is installed on the right and rear right top portions of the helmet shell and is configured to protect the right and rear right top portions of the user's head (e.g., above and behind the user's right ear).

p-0037Further, the left and right front pads <b>166</b> and <b>170</b> of the rear impact pad array <b>106</b> comprise a first curved edge <b>172</b> that forms a portion of rear air channels <b>208</b> when the impact liner <b>100</b> installed in the helmet shell <b>200</b>. As illustrated in <figref idrefs="DRAWINGS">FIG. 2A</figref>, the rear air channels <b>208</b> are formed between the first curved edges <b>172</b> of the left and right front pads <b>166</b> and <b>170</b>, the longitudinal edges <b>174</b> of the second central pad <b>162</b>, and the interior of the helmet shell <b>200</b>. The rear air channels <b>208</b> are in fluid communication with the front, middle, and transverse air channels <b>202</b>, <b>204</b>, and <b>206</b>. Further, the left and right front pads <b>166</b> and <b>170</b> and the left and right rear pads <b>164</b> and <b>168</b> of the rear impact pad array <b>106</b> comprise a second curved edge <b>176</b> configured such that, when the impact liner <b>100</b> installed in the helmet shell <b>200</b>, the pads do not cover the ears of the user.

p-0038When the impact liner <b>100</b> is installed in the helmet shell <b>200</b>, the front, middle, and rear impact pad arrays <b>102</b>, <b>104</b>, and <b>106</b> of the impact liner collectively cover between about 50% and 100% of the interior surface area of a helmet shell. For example, in a preferred embodiment, the front, middle, and rear impact pad arrays <b>102</b>, <b>104</b>, and <b>106</b> of the impact liner <b>100</b> are shaped and configured to cover the interior surface of a military helmet shell to protect the head of the user. Examples of such military helmet shells include a US Army Advanced Combat Helmet (ACH), a US Marine Corp Lightweight Helmet, an Enhanced Combat Helmet (ECH), a Personal Armor System for Ground Troops (PASGT) helmet, or other typical ballistic helmet shells. In one embodiment, the front, middle, and rear impact pad arrays <b>102</b>, <b>104</b>, and <b>106</b> of the impact liner <b>100</b> collectively cover about 80% of the interior surface area of a military helmet shell.

p-0039Further, when the impact liner <b>100</b> is installed in a helmet shell <b>200</b>, the impact liner forms a ventilation system configured to cool the user's head. As illustrated in <figref idrefs="DRAWINGS">FIG. 2A</figref>, the ventilation system comprises the front, middle, transverse, and rear air channels <b>202</b>, <b>204</b>, <b>206</b>, and <b>208</b>, which collectively form a network of air channels. Further, gaps between the various pads of the impact pad arrays form air channels that fluidly communicate with the front, middle, transverse, and rear air channels <b>202</b>, <b>204</b>, <b>206</b>, and <b>208</b> and form a portion of the network of air channels. The ventilation system is configured such that external air is permitted to flow through front and transverse air channel openings <b>220</b> and <b>260</b> and throughout the network of air channels. When the user's head is placed against the pads of the impact liner <b>100</b>, the air in the network of air channels flows over the user's head to cool the user's head. Further, air within the helmet shell <b>200</b> (e.g., heated air) is permitted to escape out the front and transverse air channel openings <b>220</b> and <b>260</b> through the network of air channels.

p-0040<figref idrefs="DRAWINGS">FIGS. 2B and 2C</figref> illustrate the impact liner <b>100</b> of the impact liner system installed in the helmet shell <b>200</b> and including air channel inserts <b>300</b> according to an embodiment of the present application. As illustrated, the air channel inserts <b>300</b> are positioned in the front air channels <b>202</b> of the impact liner <b>100</b>. However, the air channel inserts <b>300</b> may be positioned in any one or more of the air channels of the impact liner <b>100</b> and at any location within the air channel. Further, the air channel insert <b>300</b> may be made of a variety of materials, such as, for example, thermoplastic urethane (TPU), polypropylene, polyethylene, ABS plastic, rubber, or ethylene propylene diene Monomer (M-class) rubber (EPDM). In a preferred embodiment, the air channel insert <b>300</b> is an injected molded piece of Texin® TPU.

p-0041The air channel inserts <b>300</b> are configured to prohibit at least a portion of the air channels from collapsing when the helmet is installed on the user's head. For example, any one or more edges of an impact pad may collapse into the air channel when the user's head (e.g., the user's forehead) is pressed against the impact pad. The air channel insert <b>300</b> is configured with vertical walls that prohibit one or more edges of the impact pads from collapsing into the air channel. As such, the air channel remains open such that air is permitted to flow through the network of air channels of the impact liner <b>100</b>.

p-0042Openings <b>302</b> in the top <b>304</b> of the air channel insert <b>300</b> permit the air flowing through the air channel insert to flow over the portion of the user's head that is adjacent to the top of the insert. Further, the air channel insert <b>300</b> may be flexible, or comprise features that permit the insert to flex, such that it may be bent to conform to the curvature of the interior of the helmet shell <b>200</b>. Further, portions of the air channel insert <b>300</b> may be configured to attach the insert to the impact liner <b>100</b> (e.g., to the liner material) and/or to the helmet shell <b>200</b>.

p-0043<figref idrefs="DRAWINGS">FIGS. 3A and 3B</figref> illustrate an air channel insert <b>400</b> according to an embodiment of the present application. As shown, the air channel insert <b>400</b> includes a body portion <b>410</b> having a top <b>404</b> and vertical side walls <b>406</b> disposed about a centerline C_Lof the insert.

p-0044Openings <b>402</b> in the top <b>404</b> of the body portion <b>410</b> permit the air flowing through the air channel insert <b>400</b> to flow over the portion of the user's head that is adjacent to the top of the insert. As illustrated in <figref idrefs="DRAWINGS">FIG. 3B</figref>, the body portion <b>410</b> of the air channel insert <b>400</b> may also be curved such that it conforms to the curvature of the interior of the helmet shell <b>200</b> and/or the curvature of the impact liner <b>100</b>. Further, the vertical side walls <b>406</b> of the body portion <b>410</b> are configured prohibit one or more edges of the impact pads from collapsing into the air channel. As such, the air channel insert <b>400</b> is configured to be positioned within an air channel such that the vertical side walls <b>406</b> are adjacent one or more edges of the impact pads.

p-0045As illustrated in <figref idrefs="DRAWINGS">FIGS. 3A and 3B</figref>, the body portion <b>410</b> of the air channel insert <b>400</b> includes a first portion <b>412</b> and a second portion <b>414</b> connected together by a thin piece of material <b>416</b> that acts as a flexible membrane or hinge. The thin piece of material <b>416</b> is substantially perpendicular to the centerline C_Lof the insert <b>400</b>. The thin piece of material <b>416</b> permits the first portion <b>412</b> to move or flex relative to the second portion <b>414</b> such that the air channel insert <b>400</b> may be bent to conform to the curvature of the interior of the helmet shell <b>200</b>. In other embodiments, the thin piece of material <b>416</b> may be located at a variety of locations on the insert <b>400</b>. For example, the thin piece of material <b>416</b> may be substantially parallel to the centerline C_Lof the insert <b>400</b> to permit bending of the insert about the centerline.

p-0046Further, attachment members <b>420</b>, or flanges, extend outward from the body portion <b>410</b> of the insert <b>400</b>. As shown, each attachment member <b>420</b> extends substantially perpendicular to the centerline C_Lof the insert <b>400</b> and includes a slot <b>422</b>. The slot <b>422</b> of each attachment member <b>420</b> is substantially perpendicular to the centerline C_Lof the insert <b>400</b> and substantially aligned with the thin piece of material <b>416</b>. As such, the slot <b>422</b> in each attachment member <b>420</b> facilitates bending of the first portion <b>412</b> of the insert <b>400</b> relative to the second portion <b>414</b>. Further, a fastener, such as, for example, a screw, rivet, pin, clip, snap, hook and loop, or the like, may be received in the slot <b>422</b> to couple the air channel insert <b>400</b> to the impact liner <b>100</b> and/or the helmet shell <b>200</b>. The air channel insert <b>400</b>, such as one or more attachment members <b>420</b> of the insert, may also include an indicator to indicate proper positioning of the air channel insert (e.g., an F arrow indicator which indicates the direction toward the front of the helmet).

p-0047As illustrated in <figref idrefs="DRAWINGS">FIGS. 3A and 3B</figref>, the leading and trailing edges <b>432</b> and <b>434</b> of the top <b>404</b> of the air channel insert <b>400</b> are rounded to provide more comfort to the user when the insert rests against the user's head and prohibit the edges from catching on or tearing the impact liner <b>100</b>. However, in other embodiments, the edges <b>432</b> and <b>434</b> may or may not be rounded. For example, <figref idrefs="DRAWINGS">FIGS. 3C and 3D</figref> illustrate an air channel insert <b>450</b> according to another embodiment of the present application. The air channel insert <b>450</b> is similar to the air channel insert <b>400</b> shown in <figref idrefs="DRAWINGS">FIGS. 3A and 3B</figref>. However, the leading and trailing edges <b>452</b> and <b>454</b> of the top <b>460</b> of the air channel insert <b>450</b> are not rounded. Further, the top <b>460</b> of the air channel insert <b>450</b> includes less openings <b>462</b> than the top <b>404</b> of the air channel insert <b>400</b> illustrated in <figref idrefs="DRAWINGS">FIGS. 3A and 3B</figref>.

p-0048In certain embodiments, an air channel insert may be attached to the liner material of the impact liner. For example, <figref idrefs="DRAWINGS">FIG. 4</figref> is a partial bottom view of the front impact pad array <b>102</b> of the impact liner <b>100</b>. As illustrated in this embodiment, air channel inserts <b>400</b> are disposed within the front air channels <b>202</b> of the impact liner <b>100</b>. The portions <b>136</b> of the liner material <b>108</b> that at least partially form the front air channels <b>202</b> comprise slits <b>490</b> sized and configured to receive the attachment members <b>420</b> of the air channel inserts <b>400</b>. The attachment members <b>420</b> of the air channel inserts <b>400</b> are inserted through the slits <b>490</b> such that the insert is held in place relative to the liner material <b>108</b>. In some embodiments, a fastener, such as, for example, a screw, rivet, pin, clip, snap, hook and loop, or the like, may be received in one or more slots <b>422</b> of the engagement members <b>420</b> to couple the air channel inserts <b>400</b> to the liner material <b>108</b>. Further, it is contemplated that an air channel insert may be attached to the liner material <b>108</b> in any one or more of the air channels of the impact liner <b>100</b> and at any location within the air channel.

p-0049One or more comfort pads may be attached to the impact liner of the impact liner system. In certain embodiments, the comfort pads may be up to about ⅜″ thick. For example, in one embodiment, ⅛″ and/or ¼″ thick comfort pads are attached to the impact liner of the impact liner system. Various sized comfort pads may be used to adjust the sizing and fit of the helmet on the user's head. Further, the comfort pads may be a variety of shapes and sizes and may be positioned and/or configured in a variety of ways to comfort various portions of the user's head.

p-0050The comfort pads may include a soft cushion material, such as a foam, encased in a fabric material. In certain embodiments, the comfort pads comprise a flexible and resilient polyurethane foam having an average density between about 3.0 and 12.0 lbs/ft³. For example, in one embodiment, the comfort pads comprise a polyurethane foam having an average density of 4.0 lbs/ft³and the thickness of the polyurethane foam is about 0.1875 inch. One example of such a polyurethane foam is Zorbium™ Foam from Team Wendy, LLC. However, the comfort pads may comprise a variety of other types of foam or other materials, such as, for example, expanded polypropylene, expanded polystyrene, vinyl nitrile, and molded polymer structures such as thermoplastic urethane (TPU). Further, any one or more of the comfort pads may comprise a different type of material than another comfort pad.

p-0051The fabric material of the comfort pads may be a variety of fabric materials. For example, in one embodiment, the comfort pads comprise an Ultrasuede® fabric material. Further, the comfort pads may be water resistant. For example, the comfort pads may include a wicking fabric, such as polyester, nylon, or spandex. In one embodiment, the wicking fabric is GameTime Antimicrobial Wicking Fabric. In other embodiments, however, the comfort pads are moisture absorbent to absorb perspiration from the user's head. Further, in certain embodiments, the comfort pads comprise a fabric material only and do not include a foam portion.

p-0052The comfort pads are configured to be removably attached to the impact liner. For example, in one embodiment, the comfort pads are removably attached to the liner material of the impact liner with Velcro®. As described above, the comfort pads may include the hook portion of a piece of Velcro® that attaches to a loop fabric of the liner material. However, a variety of other methods of attachment may be used, such as, for example, with one or more fasteners, adhesive, clips, pins, snaps, tape, or buckles.

p-0053<figref idrefs="DRAWINGS">FIG. 5</figref> illustrates an exemplary set of comfort pads <b>500</b> and air channel inserts <b>400</b> that may be arranged and sold as a kit for a helmet shell. For example, in certain embodiments, an impact liner kit for a helmet shell comprises the impact liner <b>100</b>, at least one air channel insert (e.g., insert <b>300</b>, <b>400</b>, or <b>450</b>), and a plurality of comfort pads <b>500</b>. The impact liner <b>100</b> is configured to be installed in the interior of the helmet shell to at least partially line the front, rear, and middle portions of the helmet shell. The at least one air channel insert is configured to be installed within one or more of the plurality of air channels formed by the impact liner <b>100</b>. The plurality of comfort pads <b>500</b> are configured to be removably attached to the impact liner <b>100</b>. As illustrated in <figref idrefs="DRAWINGS">FIG. 5</figref>, the set of comfort pads <b>500</b> comprises a front comfort pad <b>502</b>, a rear comfort pad <b>504</b>, left and right comfort pads <b>508</b>, and a plurality of central comfort pads <b>506</b>. Further, as illustrated in <figref idrefs="DRAWINGS">FIGS. 6 and 7</figref> and described below, the impact liner kit may be used with a variety of different helmet shells, such as, for example, a US Army Advanced Combat Helmet (ACH), a US Marine Corp Lightweight Helmet, an Enhanced Combat Helmet (ECH), a Personal Armor System for Ground Troops (PASGT) helmet, or other typical ballistic helmet shells.

p-0054<figref idrefs="DRAWINGS">FIGS. 6 and 7</figref> illustrate impact liner systems <b>600</b> and <b>700</b> according to embodiments of the present application. The impact liner system <b>600</b> shown in <figref idrefs="DRAWINGS">FIG. 6</figref> comprises the impact liner <b>100</b> installed in an Advanced Combat Helmet (ACH) shell <b>610</b>, one or more comfort pads <b>500</b> removably attached to the impact liner, and air channel inserts <b>450</b> disposed within air channels of the impact liner. The impact liner system <b>700</b> shown in <figref idrefs="DRAWINGS">FIG. 7</figref> comprises the impact liner <b>100</b> installed in an Advanced Combat Helmet high cut shell <b>710</b>, one or more comfort pads <b>500</b> removably attached to the impact liner, and air channel inserts <b>450</b> disposed within air channels of the impact liner.

p-0055As illustrated in <figref idrefs="DRAWINGS">FIGS. 6 and 7</figref>, the impact liner systems <b>600</b> and <b>700</b> comprise a front comfort pad <b>502</b>, a rear comfort pad <b>504</b>, left and right side comfort pads <b>508</b>, and central comfort pads <b>506</b>. The comfort pads of the impact liner systems <b>600</b> and <b>700</b> may be various sizes to adjust the sizing and fit of the helmet shell <b>610</b> and <b>710</b> on the user's head. Further, the comfort pads may be a variety of other shapes and sizes and may be positioned and/or configured in a variety of ways to comfort various portions of the user's head.

p-0056As illustrated in <figref idrefs="DRAWINGS">FIGS. 6 and 7</figref>, the front comfort pad <b>502</b> is removably attached to the impact pads of the front impact pad array <b>102</b> and extends across the front and front side portions of the helmet shell <b>610</b>. The front comfort pad <b>502</b> is positioned to provide comfort across the user's forehead and temples. The rear comfort pad <b>504</b> is removably attached to the impact pads of the rear impact pad array <b>106</b> and extends across the rear and rear side portions of the helmet shell <b>610</b>. The rear comfort pad <b>504</b> is positioned to provide comfort across the rear and rear sides of the user's head (e.g., behind the user's ears). The right and left side comfort pads <b>508</b> are removably attached to the impact pads of the middle and rear impact pad arrays <b>104</b> and <b>106</b> and extend along the side portions of the helmet shell <b>610</b>. The side comfort pads <b>508</b> are positioned to provide comfort along the right and left sides of the user's head (e.g., above the user's ears). The central comfort pads <b>506</b> are removably attached to the impact pads of the front and rear impact pad arrays <b>102</b> and <b>106</b> and along the central portion of the helmet shell <b>610</b>. The central comfort pads <b>506</b> are positioned to provide comfort to the top of the user's head. In other embodiments, one or more central comfort pads <b>506</b> may also be attached to the impact pads of the middle impact pad array <b>104</b>.

p-0057When the impact liner <b>100</b> is installed in the helmet shell <b>610</b> and <b>710</b>, the impact liner forms a ventilation system configured to cool the user's head. For example, as illustrated in <figref idrefs="DRAWINGS">FIGS. 6 and 7</figref>, the impact liner <b>100</b> comprises a plurality of front, middle, rear, and transverse air channels which collectively form a network of air channels. As shown, front air channels are formed between the impact pads <b>120</b>, <b>122</b>, <b>124</b>, and <b>126</b> of the front impact pad array <b>102</b>, middle air channels are formed between the impact pads <b>140</b>, <b>142</b>, <b>144</b> of the middle impact pad array <b>104</b>, and rear air channels are formed between the impact pads <b>162</b>, <b>166</b>, and <b>170</b> of the rear impact pad array <b>106</b>. Further, transverse air channels are formed between the impact pads <b>140</b>, <b>142</b>, <b>144</b> of the middle impact pad array <b>104</b>, the impact pads <b>122</b>, <b>124</b>, and <b>126</b> of the front impact pad array <b>102</b>, and the impact pads <b>162</b>, <b>166</b>, and <b>170</b> of the rear impact pad array <b>106</b>. Still further, gaps between the various impact pads of the impact pad arrays <b>102</b>, <b>104</b>, <b>106</b> form air channels that fluidly communicate with the front, middle, rear, and transverse air channels and form a portion of the network of air channels.

p-0058As illustrated in <figref idrefs="DRAWINGS">FIGS. 6 and 7</figref>, the ventilation system is configured such that air A is permitted to flow in and out of the front and transverse air channel openings and throughout the network of air channels. When the user's head is placed against the impact pads of the impact liner <b>100</b> and/or the comfort pads, the air A in the network of air channels flows over the user's head to cool the user's head. Further, air A that is within the helmet shell <b>610</b> (e.g., heated air) is permitted to escape out the front and transverse air channel openings through the network of air channels.

p-0059As illustrated in <figref idrefs="DRAWINGS">FIGS. 6 and 7</figref>, the air channel inserts <b>450</b> are disposed in two front air channels, a right side transverse air channel, and a left side transverse air channel of the impact liner <b>100</b>. The air channel inserts <b>450</b> are also positioned adjacent the openings of the air channels. Further, the front comfort pad <b>502</b> and side comfort pads <b>508</b> at least partially cover the top of the air channel inserts <b>450</b>. As such, the top of the air channel inserts <b>450</b> prohibit the front and side comfort pads <b>502</b> and <b>508</b> from being pressed into the air channels and at least partially blocking the flow of air A through the network of air channels. For example, the forehead of the user may press against the front comfort pad <b>502</b>, or the side of the user's head may press against the side comfort pads <b>508</b>, and push a portion of the pad into the air channel. It is contemplated that the air channel inserts <b>450</b> may be positioned and configured in a variety of ways to prohibit at least a portion of any one or more of the comfort pads <b>500</b> from blocking an air channel.

p-0060As described herein, when one or more components are described as being connected, joined, affixed, coupled, attached, or otherwise interconnected, such interconnection may be direct as between the components or may be in direct such as through the use of one or more intermediary components. Also as described herein, reference to a “member,” “component,” or “portion” shall not be limited to a single structural member, component, or element but can include an assembly of components, members or elements.

p-0061While the present invention has been illustrated by the description of embodiments thereof, and while the embodiments have been described in considerable detail, it is not the intention of the applicants to restrict or in any way limit the scope of the invention to such details. Additional advantages and modifications will readily appear to those skilled in the art. For example, component geometries, shapes, and dimensions can be modified without changing the overall role or function of the components. Therefore, the inventive concept, in its broader aspects, is not limited to the specific details, the representative device, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's general inventive concept.

p-0062While various inventive aspects, concepts and features of the inventions may be described and illustrated herein as embodied in combination in the exemplary embodiments, these various aspects, concepts and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof. Unless expressly excluded herein all such combinations and sub-combinations are intended to be within the scope of the present inventions. Still further, while various alternative embodiments as to the various aspects, concepts and features of the inventions—such as alternative materials, structures, configurations, methods, devices and components, alternatives as to form, fit and function, and so on—may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the inventive aspects, concepts or features into additional embodiments and uses within the scope of the present inventions even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present disclosure, however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated. Moreover, while various aspects, features and concepts may be expressly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts and features that are fully described herein without being expressly identified as such or as part of a specific invention, the inventions instead being set forth in the appended claims. Descriptions of exemplary methods or processes are not limited to inclusion of all steps as being required in all cases, nor is the order that the steps are presented to be construed as required or necessary unless expressly so stated.