System and methods for designing and manufacturing a bespoke protective sports helmet

Patent metadata

Field	Value
Publication number	US-11213736-B2
Application number	US-202017026882-A
Country	US
Kind code	B2
Filing date	Sep 21, 2020
Priority date	Jul 20, 2016
Publication date	Jan 4, 2022
Grant date	Jan 4, 2022

Abstract

A bespoke protective sports equipment to be worn by a player engaged in a sporting activity is provided. The bespoke sports equipment system includes methods for acquiring, storing and processing a player's unique data, namely the anatomical features of the body part against which the bespoke equipment is worn. The systems also includes methods of using the player's unique data to manufacture the bespoke protective equipment with a custom formed internal padding assembly that substantially corresponds to the player's unique data. The system and method allows for the design and manufacture of bespoke protective sports equipment that is purposely designed and manufactured to match the anatomical specifications of the player's body part.

First claim

The invention claimed is:

1. A method of assembling a protective sports helmet to be worn by a player while participating in a sports activity, comprising:
obtaining head data from a player's head using a scanning device;
creating a three-dimensional model of the player's head from the obtained head data;
providing a plurality of digital pad models;
providing a three-dimensional helmet model;
forming an aligned three-dimensional model of the player's head by positioning the three-dimensional model of the player's head within the three-dimensional helmet model;
comparing the aligned three-dimensional model of the player's head against a reference surface associated with the three-dimensional helmet model to confirm that the aligned three-dimensional model of the player's head does not penetrate the reference surface;
if the aligned three-dimensional model of the player's head does not penetrate the reference surface, selecting a digital pad model from the plurality of digital pad models based upon a comparison of: (i) the aligned three-dimensional model of the player's head, and (ii) the plurality of digital pad models;
providing a group of pre-manufactured pads and a shell of the protective sports helmet;
obtaining a pre-manufactured pad from the group of pre-manufactured pads based on the selected digital pad model; and
installing the obtained pre-manufactured pad into the shell of the protective sports helmet.

2. The method of claim 1 , wherein the step of obtaining head data from the player's head using the scanning device further includes:
selecting a scanning helmet having a size;
placing the scanning helmet on the player's head; and
capturing a helmet scan of the player wearing the scanning helmet with the scanning device.

3. The method of claim 1 , wherein the step of forming the aligned three-dimensional model of the player's head by positioning the three-dimensional model of the player's head within the three-dimensional helmet model includes moving the three-dimensional model of the player's head either forward or backward based on the player's playing position or playing level.

4. The method of claim 1 , wherein the step of forming the aligned three-dimensional model of the player's head by positioning the three-dimensional model of the player's head within the three-dimensional helmet model includes moving the three-dimensional model of the player's head either forward or backward based on data collected from an on-field wearable monitoring system worn by the player.

5. The method of claim 1 , further comprising the step of replacing the aligned three-dimensional model of the player's head with a modified three-dimensional model of the player's head, wherein said modified three-dimensional model of the player's head is created by inwardly adjusting the aligned three-dimensional model of the player's head by a predetermined amount.

6. The method of claim 5 , further comprising the step of forming a bespoke pad with a thickness based on: (i) a portion of the modified three-dimensional model of the player's head, and (ii) the three-dimensional helmet model.

7. The method of claim 6 , wherein inwardly adjusting the aligned three-dimensional model of the player's head by a predetermined amount results in an increase of the thickness of the bespoke pad.

8. The method of claim 6 , wherein the step of forming the bespoke pad includes selecting a compression deflection rating of the bespoke pad based on at least one of the following factors: i) the player's impact history, ii) the player's skill level, or iii) the player's position while participating in the sports activity.

9. The method of claim 1 , wherein an inner surface of the obtained pre-manufactured pad does not match an outer surface of the player's head.

10. The method of claim 1 , wherein the plurality of digital pad models contain: (i) a first digital pad model having a first thickness, and (ii) a second digital pad model having a second thickness; and
wherein the group of pre-manufactured pads contain: (i) a first pre-manufactured pad having a first pad thickness equal to the a thickness of the first digital pad model, and (ii) a second digital pad having a second pad thickness equal to the second thickness of the second digital pad model.

11. The method of claim 1 , wherein the step of selecting one digital pad model from the plurality of digital pad models based upon the comparison of: (i) the aligned three-dimensional model of the player's head, and (ii) the plurality of digital pad models, further includes determining measurements between the aligned three-dimensional model of the player's head and the plurality of digital pad models.

12. The method of claim 1 , wherein the step of selecting one digital pad model from the plurality of digital pad models based upon the comparison of: (i) the aligned three-dimensional model of the player's head, and (ii) the plurality of digital pad models, further includes selecting the digital pad model that will cause the obtained pre-manufactured pad to be compressed a predetermined amount when the protective sports helmet is worn by the player and prior to an impact being received by the protective sports helmet.

13. The method of claim 1 , further comprising the step of providing a larger three-dimensional helmet model if the aligned three-dimensional model of the player's head penetrates the reference surface.

14. A method of assembling a protective sports helmet to be worn by a player while participating in a sports activity, comprising:
obtaining head data from a player's head using a scanning device;
creating a model of the player's head from the obtained head data within a computer software program;
providing a helmet shell model and a group of pre-manufactured pad models within the computer software program;
forming an aligned model of the player's head by moving the model of the player's head in the helmet model within the computer software program; and
identifying a pre-manufactured pad model from the group of pre-manufactured pad models, wherein said identified pre-manufactured pad model is suitable for installation in the helmet model based on a comparison of the helmet model and the aligned model of the player's head.

15. The method of claim 14 , wherein the step of obtaining head data from the player's head using the scanning device further includes:
selecting a fitting helmet having a size;
placing the fitting helmet on the player's head; and
capturing data of the player wearing the fitting helmet.

16. The method of claim 14 , wherein the step of aligning the model of the player's head within the helmet model includes modifying the aligned model of the player's head by moving the model of the player's head either forward or backward based on the player's playing position or playing level.

17. The method of claim 14 , further comprising the steps of:
providing a group of pre-manufactured pads;
providing a helmet shell;
selecting a pre-manufactured pad from the group of pre-manufactured pads based on the identified pre-manufactured pad model; and
installing the selected pre-manufactured pad within the helmet shell.

18. The method of claim 14 , wherein the step of identifying the pre-manufactured pad model from the group of pre-manufactured pad models, wherein said identified pre-manufactured pad model is suitable for installation in the helmet model based on the comparison of the helmet model and the aligned model of the player's head includes selecting a pad model with a thickness based on at least one of the

Assignees

• Riddell

Inventors

• Bologna Vittorio
• GILLOGLY Murphy
• Tryner Andrew
• Ide Thad M

Classifications

• A42C2/007 Primary

  Manufacturing custom-sized helmets · CPC title

• A42B3/127

  with removable or adjustable pads · CPC title

• A63B71/1225

  for the legs, e.g. thighs, knees, ankles, feet · CPC title

• A42C2/002

  In-mould forming · CPC title

• A63B2071/125

  for the knee · CPC title