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  Custom-fitted helmet and method of making the sameUSPTO Application #: 20060101559Title: Custom-fitted helmet and method of making the same Abstract: A helmet liner that is custom-fitted to a wearer's head, and methods of making the liner, are provided. To make the liner, scanning equipment directly scans the person's head to generate computer-readable data containing a surface map of the head. This data then is used by suitable machining equipment to machine a custom-fitted liner from a universal liner blank, whose resulting convex surface will substantially conform to the shape and contour of the person's head. The scanning equipment desirably is or includes one or a plurality of lasers. A mobile platform including both the scanning and the machining equipment also is provided. (end of abstract) Agent: Pearne & Gordon LLP - Cleveland, OH, US Inventors: Dan T. Moore, Kathleen M. Novak USPTO Applicaton #: 20060101559 - Class: 002410000 (USPTO) Related Patent Categories: Apparel, Guard Or Protector, For Wearer's Head The Patent Description & Claims data below is from USPTO Patent Application 20060101559. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/620,906 filed Oct. 21, 2004, and also is a continuation-in-part of U.S. patent application Ser. No. 10/933,580 filed Sep. 3, 2004, which is a continuation-in-part of U.S. patent application Ser. No. 10/727,725 filed Dec. 4, 2003, which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/432,193 filed on Dec. 6, 2002, all of which are incorporated herein by reference. BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The invention relates to a method of making a custom-fitted helmet. More particularly, it relates to a method for making a custom-fitted helmet having an impact energy-absorbing liner having an inner surface that substantially conforms to the shape of the wearer's head. [0004] 2. Description of Related Art [0005] Helmets having an impact energy-absorbing liner are known for all sorts of applications, including cycling, football and other contact sports, medical intervention for persons prone to seizures, industrial protection such as for manufacturing and construction workers, military and other aircraft pilot protection, etc. In all of these applications, the impact energy-absorbing liner is designed to absorb and/or dissipate energy from an impact at the outer shell of the helmet before it is transmitted to the wearer's head. In this manner the wearer's head is at least partially shielded or protected from what otherwise would be the full impact force resulting from the impact. [0006] Conventionally, helmets are supplied in a plurality of standard sizes, e.g., large, medium, small. Sometimes the standard sizes are based on average head circumference, e.g. 14, 14.5, 15, 15.5, 16, inches, etc. A problem with this method of sizing helmets is that the helmets are sized based on universal standards that are not specific to any individual who will actually wear and depend on the helmet for head protection. While a standard sized helmet may provide adequate protection in some instances, it is not fitted to the unique shape and contour of the particular wearer's head, and therefore is prone to fit too tightly in certain aspects or along certain locations of the head while fitting too loosely in others. A too loosely fitting helmet can be harmful because the initial impact against the outer helmet shell can be transferred to the head during a second impact between the head and the loosely fitting interior surface of the helmet. Whereas a too tightly fitting helmet is uncomfortable to the wearer and can actually cause injury. [0007] Currently, "off-the-shelf" helmets are fitted so that they fit snugly in the tightest dimension of the head--this could be from front to back, or it could be from side to side. The other dimension (front to back or side to side) is then looser--often with a gap of 1/2 inch or more on each side. This gap is often filled with non-energy-absorbing foam. As an example, a high performance ski helmet typically has approximately 1 inch of energy-absorbing polymer. The 1/2 inch of unused space on each side of the helmet comes at a high price from an energy-absorbing standpoint, because even at moderate impact speeds (e.g. 6 m/s) that extra 1/2 inch of energy-absorbing foam would result in about a 30% improvement in g-force attenuation prior to reaching the wearer's head. At higher speed impacts the improvement would generally be higher due to the fact that thinner foam will `bottom out` sooner as impact speed increases. [0008] For these reasons, it is important and desirable that the inner surface of the helmet fit as uniformly and snugly as possible about the shape and contour of the individual wearer's head, without being so tight as to result in discomfort or injury. Conventionally, helmets have been fit to a wearer's head either by shimming the inside of the helmet using energy-absorbing or comfort fitting foam pieces of varying thickness until the proper fit is achieved, or by installing a series of foam pieces of different thickness to provide a proper fit. There are two disadvantages of these methods: 1. It is difficult when fitting a helmet to know when you have achieved the proper fit. It is a trial and error process that requires more training than is typically available in retail stores. An improperly fitted helmet can lead to serious consequences. 2. Energy-absorbing foam is more effective if it is in one piece. The reason for this is that a significant amount of energy is absorbed in the foam by pumping air through foam--the larger the piece of foam, the longer the path the air must take, and the better the energy-absorption. If the foam is in several layers or discrete pieces, it is easier for the air to escape and the energy-absorption properties are reduced. [0009] Some manufacturers attempt to fit their helmets to wearer's heads using "fitting pads" of highly compressible foam that has no appreciable energy-absorbing capability. These fitting pads help keep the helmet tight on the head rather than provide an additional layer of energy-absorptive material. As will be apparent from the above discussion, the use of any more than a minimum of fitting-foam is a waste of critical space in a helmet that could be used to absorb additional energy. [0010] There is a need in the art for a method of making a custom-fitted helmet that is economical and comfortable to the wearer, where the energy-absorbing liner is snugly and uniformly fitted to the shape and contour of the head. SUMMARY OF THE INVENTION [0011] A method of making an energy-absorbing liner that is custom-fitted to a wearer's head is provided. The method includes the following steps: a) directly scanning a person's head and generating computer-readable data including a surface map of the person's head; b) providing a pre-made energy-absorbing liner blank having at least one surface; and c) machining the at least one surface of the energy-absorbing liner blank, based on the computer-readable data, to provide a convex surface therein whose shape and contour substantially conform to the shape and contour of the person's head. [0012] An apparatus for producing a custom-fitted energy-absorbing liner is provided. The apparatus includes means for directly scanning a person's head to generate computer-readable data comprising a surface map of said person's head, and means to machine an impact energy-absorbing liner blank to provide a convex surface therein whose shape and contour substantially conform to the shape and contour of said person's head. Both the means for scanning the head and the means for machining the liner blank are provided on a mobile platform. BRIEF DESCRIPTION OF THE DRAWINGS [0013] FIG. 1 is a side view of a beanie cap for preparing a headform that can be used to make an energy-absorbing liner for a helmet according to the invention having an inner surface substantially conforming to the shape and contour of a person's head. [0014] FIG. 2 is a side view of a person's head to which the beanie cap of FIG. 1 has been applied and rolled down and/or stretched over, substantially conforming to the shape and contour of the person's head. [0015] FIG. 3 is a side view of the person's head from FIG. 2 prior to application of the beanie cap, and showing a barrier applied over the person's head according to the invention, and also showing a piece of flexible tubing attached along the centerline of the rear of the person's head as a scissor guide. [0016] FIG. 4 is a top plan view of a heat-softenable plastic sheet that can applied over a person's head and used to make a headform according to the invention for subsequently making an energy-absorbing liner for a helmet having an inner surface substantially conforming to the shape and contour of the person's head. [0017] FIG. 5 is a top plan view of the heat-softenable plastic sheet of FIG. 4, shown positioned atop a person's head prior to folding the individual elements over the head to conform to the head's shape. [0018] FIG. 6 is a side view of the heat-softenable plastic sheet of FIGS. 4-5, shown positioned over and substantially conforming to the shape and contour of the person's head. [0019] FIG. 7 is a side view of a person's head over which a curable tape has been wrapped to provide a headform according to the invention for subsequently making an energy-absorbing liner for a helmet having an inner surface substantially conforming to the shape and contour of the person's head. [0020] FIG. 8 is a side view of a person's head having a hardened headform substantially conforming to the shape and contour of the person's head which was made using the beanie cap of FIGS. 1-2, where a tight fitting elastic hood has been applied over the head prior to application of the beanie cap to protect the person's eyes, hair and scalp. Continue reading... Full patent description for Custom-fitted helmet and method of making the same Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Custom-fitted helmet and method of making the same patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Custom-fitted helmet and method of making the same or other areas of interest. ### Previous Patent Application: Brief with pockets for thermal inserts Next Patent Application: Adjustable headband Industry Class: Apparel ### FreshPatents.com Support Thank you for viewing the Custom-fitted helmet and method of making the same patent info. 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