权利要求：
CLAIMS
What is claimed is:
1. A method of manufacturing a protective sports helmet comprising the following steps:
acquiring player head shape information and player position information from a plurality of players;
generating a plurality of head models for each player in the plurality of players, wherein each head model is generated from said player head shape information;
pairing each head model with player position information associated with the head shape information that was utilized to generate the head model;
separating the plurality of head models based on: (i) the player position information and (ii) unique information in the head model to generate a plurality of head shape based player (HSBP) data sets;
selecting one of the HSBP data sets;
determining a mean head shape of the selected HSBP date set, said mean head shape having a topography;
manufacturing an energy attenuation assembly that includes an inner surface with a topography that substantially matches the topography of the mean head shape; and
installing the energy attenuation assembly within a protective sports helmet.
2. The method of manufacturing a protective sports helmet according to claim 1, wherein the head shape information is collected using an image sensor contained within a non-contact scanning apparatus.
3. The method of manufacturing a protective sports helmet according to claim 1, wherein the plurality of head models are generated using a photogrammetry method.
4. The method of manufacturing a protective sports helmet according to claim 1, further comprising the step of overlying a helmet interface reference surface on the head model.
5. The method of manufacturing a protective sports helmet according to claim 4, further comprising the step of removing an extent of the head model that is beyond the region where the helmet interface reference surface overlies the head model.
6. The method of manufacturing a protective sports helmet according to claim 1, wherein said player position information includes the position the player primarily plays while engaged in the sport.
7. The method of manufacturing a protective sports helmet according to claim 1, wherein the step of separating the plurality of head models based on unique information in the head model includes analyzing the head models based upon: (i) a circumference of the head model (ii) a volume of the head model, or (iii) a surface area of the head model.
8. The method of manufacturing a protective sports helmet according to claim 1, wherein the step of separating the plurality of head models based on unique information in the head model includes analyzing the head models using principal component analysis.
9. The method of manufacturing a protective sports helmet according to claim 1, wherein each HSBP data set is statistically different from other HSBP data sets contained within the plurality of HSBP data sets.
10. The method of manufacturing a protective sports helmet according to claim 1, wherein the mean head shape of the selected HSBP date set is determined using principal component analysis.
11. The method of manufacturing a protective sports helmet according to claim 1, further comprising the step of generating a computerized helmet model that fits the HSBP data set (HSBP data set specific helmet model), wherein the HSBP data set specific helmet model has an inner surface that is in contact with a modified surface of the mean head shape.
12. The method of manufacturing a protective sports helmet according to claim 11, further comprising the step of generating an optimized helmet prototype model from the HSBP data set specific helmet model.
13. The method of manufacturing a protective sports helmet according to claim 12, wherein the step of generating the optimized helmet prototype model includes:
testing the HSBP data set specific helmet model to determine the impact responses of the HSBP data set specific helmet model;
generating a modified HSBP data set specific helmet model by altering at least one structural aspect or mechanical property of the HSBP data set specific helmet model;
testing the modified HSBP data set specific helmet model to determine the impact responses of the modified HSBP data set specific helmet model; and
selecting either the modified HSBP data set specific helmet model or the HSBP data set specific helmet model based on the impact responses.
14. The method of manufacturing a protective sports helmet according to claim 13, wherein the step of selecting either the modified HSBP data set specific helmet model or the HSBP data
set specific helmet model is further based upon at least one of: (i) peak linear acceleration, (ii) peak rotational acceleration, (iii) peak HITsp, and (iv) distance until the helmet bottoms out.
15. The method of manufacturing a protective sports helmet according to claim 12, further comprising the step of generating a complete helmet model from the optimized helmet prototype model by selecting a combination of structural properties and chemical compositions of an internal energy attenuation assembly that have substantially the same mechanical properties as the optimized helmet prototype model.
16. The method of manufacturing a protective sports helmet according to claim 15, wherein the selection of the structural properties of the internal energy attenuation assembly include the selection of at least one of the following: (i) lattice cell type, (ii) lattice angle, and (iii) lattice density.
17. The method of manufacturing a protective sports helmet according to claim 15, further comprising the step of manufacturing a physical prototype helmet from the complete helmet model using an additive manufacturing process.
18. The method of manufacturing a protective sports helmet according to claim 1, wherein the energy attenuation assembly includes at least one energy attenuation member having (i) a first lattice region with a first lattice cell type and (ii) a second lattice region with a second lattice cell type.
19. The method of manufacturing a protective sports helmet according to claim 18, wherein the protective sports helmet is an American football helmet.
20. A method of manufacturing a protective sports helmet comprising the following steps:
acquiring player impact information and player position information from a plurality of players;
generating an impact matrix for each player in the plurality of players, wherein each impact matrix is generated from said player impact information;
pairing each impact matrix with player position information associated with the impact information that was utilized to generate the impact matrixes;
separating the plurality of impact matrixes based on: (i) the player position information and (ii) unique information in the impact matrix to generate a plurality of impact based player (IBP) data sets;
selecting one of the IBP data sets;
manufacturing an energy attenuation assembly that includes mechanical properties that selected based upon the information contained within the impact matrix of the selected IBP data set;
installing the energy attenuation assembly within a protective sports helmet.
21. The method of manufacturing a protective sports helmet according to claim 20, wherein the impact information is collected using in-helmet impact sensor.
22. The method of manufacturing a protective sports helmet according to claim 20, wherein said player position information includes the position the player primarily plays while engaged in the sport.
23. The method of manufacturing a protective sports helmet according to claim 20, wherein the step of separating the plurality of impact matrixes based on unique information in the impact matrix includes analyzing the impact matrixes based upon: (i) an average linear impact magnitude, (i) an average rotational impact magnitude, (iii) an average impact location, or (iv) an average HITsp score.
24. The method of manufacturing a protective sports helmet according to claim 20, wherein the step of separating the plurality of impact matrixes based on unique information in the impact matrix includes analyzing the impact matrixes using principal component analysis.
25. The method of manufacturing a protective sports helmet according to claim 20, wherein each IBP data set is statistically different from other IBP data sets contained within the plurality of IBP data sets.
26. The method of manufacturing a protective sports helmet according to claim 20, further comprising the step of generating an optimized helmet prototype model from a generic helmet.
27. The method of manufacturing a protective sports helmet according to claim 26, wherein the step of generating the optimized helmet prototype model includes:
testing the generic helmet to determine the impact responses of the generic helmet using a testing protocol derived from the impact matrix of the selected IBP data set;
generating a modified generic helmet by altering at least one structural aspect or mechanical property of the generic helmet;
testing the modified generic helmet to determine the impact responses of the modified generic helmet using the testing protocol derived from the impact matrix of the selected IBP data set; and
selecting either the modified generic helmet or the generic helmet based on the impact responses.
28. The method of manufacturing a protective sports helmet according to claim 27, wherein the step of selecting either the modified IBP data set specific helmet or the IBP data set specific helmet is further based upon at least one of: (i) peak linear acceleration, (ii) peak rotational acceleration, (iii) peak HITsp, and (iv) distance until the helmet bottoms out.
29. The method of manufacturing a protective sports helmet according to claim 26, further comprising the step of generating a complete helmet model from the optimized helmet prototype model by selecting a combination of structural properties and chemical compositions of an internal energy attenuation assembly that have substantially the same mechanical properties as the optimized helmet prototype model.
30. The method of manufacturing a protective sports helmet according to claim 29, wherein the selection of the structural properties of the internal energy attenuation assembly include the selection of at least one of the following: (i) lattice cell type, (ii) lattice angle, and (iii) lattice density.
31. The method of manufacturing a protective sports helmet according to claim 30, further comprising the step of manufacturing a physical prototype helmet from the complete helmet model using an additive manufacturing process.
32. The method of manufacturing a protective sports helmet according to claim 20, wherein the energy attenuation assembly includes at least one energy attenuation member having (i) a first lattice region with a first lattice cell type and (ii) a second lattice region with a second lattice cell type.
33. The method of manufacturing a protective sports helmet according to claim 32, wherein the protective sports helmet is an American football helmet.
34. A method of manufacturing a protective sports helmet comprising the following steps:
acquiring player head shape information, player impact information and player position information from a plurality of players;
generating a plurality of head models for each player in the plurality of players, wherein each head model is generated from said player head shape information;
pairing each head model with player position information associated with the head shape information that was utilized to generate the head model;
separating the plurality of head models based on: (i) the player position information and (ii) unique information in the head model to generate a plurality of head shape based player (HSBP) data sets;
selecting one of the HSBP data sets;
determining a mean head shape of the selected HSBP date set, said mean head shape having a topography;
generating an impact matrix for each player in the plurality of players, wherein each impact matrix is generated from said player impact information;
pairing each head model with an impact matrix associated with the head shape information that was utilized to generate the head model;
separating the plurality of impact matrixes that are paired with the head models contained within the selected HSBP data set based on unique information in the impact matrix to generate a plurality of combined head shape and impact based player (HS+IBP) data sets;
selecting one of the HS+IBP data sets;
manufacturing an energy attenuation assembly that includes: (i) an inner surface with a topography that substantially matches the topography of the mean head shape and (ii) mechanical properties that selected based upon the information contained within the impact matrix of the selected HS+IBP data set; and
installing the energy attenuation assembly within a protective sports helmet.
35. The method of manufacturing a protective sports helmet according to claim 34, wherein the head shape information is collected using an image sensor contained within a non-contact scanning apparatus.
36. The method of manufacturing a protective sports helmet according to claim 34, wherein the plurality of head models are generated using a photogrammetry method.
37. The method of manufacturing a protective sports helmet according to claim 34, further comprising the step of overlying a helmet interface reference surface on the head model.
38. The method of manufacturing a protective sports helmet according to claim 37, further comprising the step of removing an extent of the head model that is beyond the region where the helmet interface reference surface overlies the head model.
39. The method of manufacturing a protective sports helmet according to claim 34, wherein said player position information includes the position the player primarily plays while engaged in the sport.
40. The method of manufacturing a protective sports helmet according to claim 34, wherein the step of separating the plurality of head models based on unique information in the head model includes analyzing the head models based upon: (i) a circumference of the head model (ii) a volume of the head model, or (iii) a surface area of the head model.
41. The method of manufacturing a protective sports helmet according to claim 34, wherein the step of separating the plurality of head models based on unique information in the head model includes analyzing the head models using principal component analysis.
42. The method of manufacturing a protective sports helmet according to claim 34, wherein each HSBP data set is statistically different from other HSBP data sets contained within the plurality of HSBP data sets.
43. The method of manufacturing a protective sports helmet according to claim 34, wherein the mean head shape of the selected HSBP date set is determined using principal component analysis.
44. The method of manufacturing a protective sports helmet according to claim 34, further comprising the step of generating a computerized helmet model that fits the HSBP data set (HSBP data set specific helmet model), wherein the HSBP data set specific helmet model has an inner surface that is in contact with a modified surface of the mean head shape.
45. The method of manufacturing a protective sports helmet according to claim 44, further comprising the step of generating an optimized HSBP data set specific helmet model from the HSBP data set specific helmet model.
46. The method of manufacturing a protective sports helmet according to claim 45, wherein the step of generating the optimized HSBP data set specific helmet model includes:
testing the HSBP data set specific helmet model to determine the impact responses of the HSBP data set specific helmet model;
generating a modified HSBP data set specific helmet model by altering at least one structural aspect or mechanical property of the HSBP data set specific helmet model;
testing the modified HSBP data set specific helmet model to determine the impact responses of the modified HSBP data set specific helmet model; and
selecting either the modified HSBP data set specific helmet model or the HSBP data set specific helmet model based on the impact responses.
47. The method of manufacturing a protective sports helmet according to claim 46, further comprising the step of generating an optimized helmet prototype model from the optimized HSBP data set specific helmet model.
48. The method of manufacturing a protective sports helmet according to claim 47, wherein the step of generating the optimized helmet prototype model includes:
testing the optimized HSBP data set specific helmet model to determine the impact responses of the optimized HSBP data set specific helmet model using a testing protocol derived from the impact matrix of the selected HS+IBP data set;
generating a modified optimized HSBP data set specific helmet model by altering at least one structural aspect or mechanical property of the optimized HSBP data set specific helmet model;
testing the modified optimized HSBP data set specific helmet model to determine the impact responses of the modified optimized HSBP data set specific helmet model using the testing protocol derived from the impact matrix of the selected HS+IBP data set; and
selecting either the modified optimized HSBP data set specific helmet model or the optimized HSBP data set specific helmet model based on the impact responses.
49. The method of manufacturing a protective sports helmet according to claim 48, wherein the step of selecting either the modified optimized HSBP data set specific helmet model or the optimized HSBP data set specific helmet model is further based upon at least one of: (i) peak linear acceleration, (ii) peak rotational acceleration, (iii) peak HITsp, and (iv) distance until the helmet bottoms out.
50. The method of manufacturing a protective sports helmet according to claim 49, further comprising the step of generating a complete helmet model from the optimized helmet prototype model by selecting a combination of structural properties and chemical compositions of an internal energy attenuation assembly that have substantially the same mechanical properties as the optimized helmet prototype model.
51. The method of manufacturing a protective sports helmet according to claim 50, wherein the selection of the structural properties of the internal energy attenuation assembly include the selection of at least one of the following: (i) lattice cell type, (ii) lattice angle, and (iii) lattice density.
52. The method of manufacturing a protective sports helmet according to claim 51, further comprising the step of manufacturing a physical prototype helmet from the complete helmet model using an additive manufacturing process.
53. The method of manufacturing a protective sports helmet according to claim 34, wherein the energy attenuation assembly includes at least one energy attenuation member having (i) a first lattice region with a first lattice cell type and (ii) a second lattice region with a second lattice cell type.
54. The method of manufacturing a protective sports helmet according to claim 53, wherein the protective sports helmet is an American football helmet.
55. A method of testing a protective sports helmet comprising the following steps:
providing a plurality of protective sports helmets, wherein each helmet is configured for a single position that is played by a wearer of the protective sports helmet;
providing a plurality of impact test methods, wherein each impact test method is tailored to a single position that is played by the wearer of the protective sports helmet;
selecting one of the plurality of protective sports helmet;
positioning the selected protective sports helmet on a headform that is connected to an impact tester; and
applying the impact test method that corresponds to the selected protective sports helmet using the impact tester.
56. The method of testing a protective sports helmet of claim 55, wherein the step of providing the impact test method tailored to the single position that is played by the wearer of the protective sports helmet includes:
acquiring player impact information and player position information from a plurality of players;
generating an impact matrix for each player in the plurality of players, wherein each impact matrix is generated from said player impact information;
pairing each impact matrix with player position information associated with the impact information that was utilized to generate the impact matrixes;
separating the plurality of impact matrixes based on: (i) the player position information and (ii) unique information in the impact matrix to generate a plurality of impact based player (IBP) data sets;
selecting one of the IBP data sets;
developing a testing protocol by weighting the impact response values from each impact location by the weighting of the impact locations contained within the impact matrix of the selected IBP data set.
57. The method of testing a protective sports helmet of claim 55, wherein the step of separating the plurality of impact matrixes based on unique information in the impact matrix includes analyzing the impact matrixes based upon: (i) an average linear impact magnitude, (i) an average rotational impact magnitude, (iii) an average impact location, or (iv) an average HITsp score.
58. The method of manufacturing a protective sports helmet according to claim 55, wherein the step of separating the plurality of impact matrixes based on unique information in the impact matrix includes analyzing the impact matrixes using principal component analysis.
59. The method of manufacturing a protective sports helmet according to claim 55, wherein the impact information is collected using in-helmet impact sensor.
60. A protective sports helmet comprising:
a plastic shell configured to receive a head of a wearer of the protective sports helmet, the shell having:
a front region,
a crown region,
a rear region, and
two side regions depending from the crown region;
an energy attenuation assembly coupled to an inner surface of the shell, the energy attenuation assembly includes an inner surface with a topography that substantially matches a topography of a mean head shape of a selected group of players who play a specific position.
61. The protective sports helmet of claim 60, wherein the mean head shape is determined from a plurality of head models.
62. The protective sports helmet of claim 61, wherein the head models are created from player head shape information collected using a non-contact scanning device.