System and method for custom forming a protective helmet for a customer's head

Patent metadata

Field	Value
Publication number	US-10948898-B1
Application number	US-202017026475-A
Country	US
Kind code	B1
Filing date	Sep 21, 2020
Priority date	Jan 18, 2013
Publication date	Mar 16, 2021
Grant date	Mar 16, 2021

Abstract

A custom-fitted helmet and a method of making the same can comprise, at a first location, obtaining head data for a customer's head comprising a length, a width, and at least one head contour. With at least one processor, generating a computerized three-dimensional (3D) headform matching the customer's head length, width, and head contour from the head data. The 3D headform can be compared to a helmet safety standard. At a second location different from the first location, a custom-fitted helmet based on the 3D headform can be formed, wherein the custom-fitted helmet satisfies the safety standard and comprises an inner surface comprising a topography that conforms to the length, width, and at least one contour of the customer's head. The first location can be a home or a store. Obtaining the head data from photographic images of a deformable interface member disposed on the customer's head.

First claim

The invention claimed is:

1. A multi-step method of making an energy attenuation layer, comprising:
obtaining body part data from a customer's body part using a scanning device;
processing the body part data to create a computerized model of the customer's body part;
providing a computerized safety standard that includes a computerized certified surface;
positioning the computerized model of the customer's body part within the computerized certified surface of the computerized safety standard;
comparing the computerized model of the customer's body part with the computerized certified surface to assess whether the computerized model of the customer's body part extends through the computerized certified surface; and
when said computerized model of the customer's body part does not extend through the computerized certified surface, using a three dimensional printer to form the energy attenuation layer that has an inner surface with a topography that conforms to a surface that is derived from the computerized model of the customer's body part.

2. The multi-step method of claim 1 , wherein the step of using the three dimensional printer to form the energy attenuation layer includes printing a lattice structure between the inner surface of the energy attenuation layer and an outer surface of the energy attenuation layer.

3. The multi-step method of claim 2 , wherein the lattice structure is printed from a polyurethane material.

4. The multi-step method of claim 1 , wherein the step of using the three dimensional printer to form the energy attenuation layer that includes printing a plurality of separate pieces; and
further comprising the step of inserting the plurality of separate pieces into a helmet shell.

5. The multi-step method of claim 4 , wherein the helmet shell is configured as a football helmet, and wherein the plurality of separate pieces includes a first piece designed to overlie an extent of the customer's cheeks and a second piece designed to overlie an extent of the customer's brow.

6. The multi-step method of claim 1 , wherein the step of obtaining body part data from the customer's body part using the scanning device further includes: (i) obtaining a deformable interface member that has a thickness, (ii) placing the deformable interface member over the customer's body part, and (iii) capturing images of the deformable interface member that is positioned over the customer's body part.

7. The multi-step method of claim 6 , wherein the step of processing the body part data to create the computerized model of the customer's body part includes subtracting the thickness of the deformable interface member from the body part data to create the computerized model of the customer's body part.

8. The multi-step method of claim 1 , wherein the step of obtaining body part data from the customer's body part using the scanning device includes using a software program that is installed on the scanning device that guides a person through a process of collecting the body part data.

9. The multi-step method of claim 1 , further comprises a step of selecting a second computerized safety standard when the computerized model of the customer's body part extends through the computerized certified surface.

10. A multi-step method of designing an energy attenuation layer for a helmet, comprising:
obtaining head data from a customer's head using a scanning device;
processing the head data to create a three-dimensional digital model of the customer's head;
providing a three-dimensional digital model of a safety standard;
positioning the three-dimensional digital model of the customer's head within the three-dimensional digital model of the safety standard;
comparing the three-dimensional digital model of the customer's head against the three-dimensional digital model of the safety standard to assess whether the safety standard is satisfied; and
when said the safety standard is satisfied, creating a digital model of an energy attenuation layer that (i) is configured to be inserted within a helmet shell, and (ii) has an inner surface with a topography that conforms to a surface that is derived from the three-dimensional digital model of the customer's head.

11. The multi-step method of claim 10 , further comprises a step of using a three dimensional printer to form a physical energy attenuation layer from the digital model of the energy attenuation layer.

12. The multi-step method of claim 11 , wherein the step of using the three dimensional printer to form the physical energy attenuation layer includes printing a lattice structure from polyurethane.

13. The multi-step method of claim 11 , wherein the physical energy attenuation layer is comprised of a plurality of separate pieces that can be installed within the helmet shell.

14. The multi-step method of claim 10 , wherein the step of obtaining head data from the customer's head using the scanning device includes using a software program that is installed on the scanning device that guides a person through a process of collecting the head data.

15. The multi-step method of claim 10 , wherein the digital model of the energy attenuation layer includes a first portion designed to overlie an extent of the customer's cheeks and a second portion designed to overlie an extent of the customer's brow.

16. The multi-step method of claim 10 , wherein the three-dimensional digital model of the safety standard includes a certified surface; and
wherein the safety standard is satisfied when the three-dimensional digital model of the customer's head does not extend through the certified surface.

17. The multi-step method of claim 10 , wherein the three-dimensional digital model of the safety standard includes a minimum dimension that extends between a first portion of the digital model of the energy attenuation layer and an extent of the three-dimensional digital model of the safety standard;
wherein the multi-step method further includes determining an actual dimension that extends between the first portion of the digital model of the energy attenuation layer and a portion of the digital model of the customer's head; and
wherein the safety standard is satisfied when the actual dimension is greater than the minimum dimension.

18. A multi-step method of manufacturing a protective sports helmet to be worn by a player while playing a sports activity, comprising:
obtaining head data from a customer's head using a scanning device;
processing the head data to create a digital model of the customer's head;
providing a digital helmet model;
positioning the digital model of the customer's head within the digital helmet model;
generating a digital model of an energy attenuation layer that has both an inner surface that matches a surface that is derived from the digital model of the customer's head and an outer surface that is configured to be positioned within a helmet shell of the digital helmet model;
using a three dimensional printer to generate a physical energy attenuation layer from the digital model of the energy attenuation layer, and wherein the physical energy attenuation layer: (i) is made from a polyurethane material and (ii) includes a lattice structure and an inner surface with a topography that conforms to a surface that is derived from the digital model of the customer's head; and
installing the physical energy attenuation layer within a physical helmet shell.

19. The multi-step method of claim 18 , wherein the step of obtaining head data from the customer's head using the scanning device fur

Assignees

• Bell Sports Inc

Inventors

• Pietrzak Christopher T
• Lowe Michael W

Classifications

• A42B3/00 Primary

  Helmets; Helmet covers {; Other protective head coverings} ({hoods for welders A61F9/06;} defence protection helmets F41H1/04) · CPC title

• Y02P90/02

  Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS] · CPC title

• G05B2219/35217

  Cagd computer aided geometric design, sbgd scanning based geometric design · CPC title

• G05B19/4099 Primary

  Surface or curve machining, making three-dimensional [3D] objects, e.g. desktop manufacturing · CPC title

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title