Multi-layer helmet and method for making the same

1. A protective helmet to be worn by a wearer while participating in a motor sports or power sports activity, the helmet comprising:

a one-piece outer shell; and

a multi-layer liner assembly disposed within the one-piece outer shell and sized for receiving a wearer's head, the multi-layer liner assembly including an inner-layer, a middle-layer, and an outer-layer, said multi-layer liner assembly permits relative rotational movement between said layers where said movement results from an impact to the helmet while the helmet is being worn by the wearer:

the inner-layer comprising an inner surface oriented towards an inner area of the helmet, wherein the inner-layer comprises an energy management material that has a thickness that is (i) greater than a thickness of the middle-layer and (ii) less than a thickness of the outer-layer, and said inner-layer having: (i) a hardness that is greater than a hardness of the middle-layer and less than a hardness of the outer-layer and (ii) a plurality of channels, each channel extending upward from a lowermost edge of the inner-layer and being formed completely through the inner-layer whereby the inner-layer is segmented;

the middle-layer disposed adjacent an outer surface of the inner-layer, wherein the middle-layer comprises an energy management material that has a thickness that is less than both the inner-layer and the outer-layer, said middle-layer has a plurality of channels, each channel extending upward from a lowermost edge of the middle-layer and being formed completely through the middle-layer whereby the middle-layer is segmented; and

the outer-layer disposed adjacent an outer surface of the middle-layer, the outer-layer comprising an outer surface oriented towards the one-piece outer shell, wherein the outer-layer comprises an energy management material that has a thickness that both: (i) varies between a front region of the outer-layer and a crown region of the outer-layer and (ii) is greater than both the inner-layer and the middle-layer.

2. The protective helmet of claim 1 , wherein the middle-layer is coupled to the inner-layer and the outer-layer without adhesive to facilitate relative movement among the inner-layer, the middle-layer, and the outer-layer.

3. The protective helmet of claim 2 , wherein thickness of the multi-layer liner assembly is less than or equal to 50 mm.

4. The protective helmet of claim 2 , wherein at least a portion of the middle-layer is removed from a front region of the middle-layer to form an opening in said middle-layer, and wherein said removed portion does not form one of the channels in said middle-layer.

5. The protective helmet of claim 1 , wherein a topography of the inner-layer is custom fitted to match a topography of the wearer's head so that a gap between the wearer's head and the multi-layer liner assembly of the helmet is reduced or eliminated.

6. The protective helmet of claim 1 , wherein the inner-layer and the middle-layer are interlocked together by a plurality of flanges, wherein said flanges extend outwardly from the outer surface of the inner-layer and reside within recesses formed in the middle-layer.

7. The protective helmet of claim 1 , wherein the lowermost edge of the middle-layer has both: (i) a linear extent positioned in a front region of the multi-layer liner assembly and (ii) a non-linear extent positioned in a side region of the multi-layer liner assembly.

8. The protective helmet of claim 7 , wherein the lowermost edge of the middle-layer resides above an extent of a lowermost edge of the outer-layer, when the multi-layer liner assembly is installed in the one-piece outer shell.

9. A protective helmet comprising:

a one-piece outer shell; and

a multi-layer liner assembly in a pre-impact state, disposed within the one-piece outer shell and sized for receiving a wearer's head, wherein the multi-layer liner assembly includes an inner-layer, a middle-layer, and an outer-layer, said multi-layer liner assembly permits relative rotational movement between said layers where said movement results from an impact to the helmet while the helmet is being worn by the wearer:

wherein the inner-layer includes: (i) a component made from foam, (ii) an inner surface oriented towards an inner area of the helmet and (iii) a plurality of channels, each channel extending upward from a lowermost edge of the inner-layer and being formed completely through the inner-layer whereby the inner-layer is segmented;

wherein the middle-layer is disposed adjacent an outer surface of the inner-layer, wherein the middle-layer has: (i) at least one side portion with a lowermost edge that resides above an extent of a lowermost edge of the outer-layer (ii) a thickness that is less than a thickness of the outer-layer and the inner-layer, and (iii) a density greater than a density of each of the inner-layer and the outer-layer, and (iv) a plurality of channels extending completely through the middle-layer, and wherein at least two of the plurality of channels in the middle-layer are substantially aligned with at least two of the plurality of channels in the inner-layer; and

wherein the outer-layer is disposed adjacent an outer surface of the middle-layer.

10. The protective helmet of claim 9 , wherein the one-piece outer shell is a one-piece flexible plastic and is formed by either: (i) stamped, (ii) thermoformed, or (iii) injection molded.

11. The protective helmet of claim 9 , wherein: the inner-layer comprises a mid-energy management material; and the outer-layer comprises a high-energy management material.

12. The protective helmet of claim 9 , wherein the multi-layer liner assembly is arranged to provide boundary conditions at interfaces between layers of the multi-layer liner assembly to deflect energy and manage energy dissipation for low-energy, mid-energy, and high-energy impacts.

13. The protective helmet of claim 9 , wherein a topography of the inner-layer is custom fitted to match a topography of the wearer's head so that a gap between the wearer's head and the multi-layer liner assembly of the helmet is reduced or eliminated.

14. The protective helmet of claim 9 , wherein the middle-layer is mechanically coupled to the inner-layer without adhesive, which allows for relative movement between the middle-layer and inner-layer.

15. The protective helmet of claim 9 , wherein at least a portion of the middle-layer is removed from a front region of the middle-layer to form an opening in said middle-layer, and wherein said removed portion does not form one of the channels in said middle-layer.

16. A protective helmet to be worn by a player engaged in a contact sport, the protective helmet comprising:

a one-piece flexible outer shell;

a multi-layer liner assembly in a pre-impact state and disposed within the flexible outer shell, the multi-layer liner assembly including an inner-layer, a middle-layer, and an outer-layer, said multi-layer liner assembly permits relative rotational movement between said layers where said movement results from an impact to the helmet while the helmet is being worn by the wearer:

wherein the inner-layer is positioned between (i) an inner surface of the middle-layer and (ii) the player's head when the protective helmet is worn by the player, and wherein the inner-layer is mechanically coupled to the middle-layer without adhesive;

wherein the middle-layer is positioned between (i) an outer surface of the inner-layer and (ii) an inner surface of the outer-layer, said middle-layer has a greater density than a density of each of the inner-layer and the outer-layer; and

wherein the outer-layer is positioned between (i) an outer surface of the middle-layer and (ii) an inner surface of the flexible outer shell, wherein said outer-layer has a thickness that (a) is greater than a thickness of each of the inner-layer and the middle-layer and (b) varies between a front region of the outer-layer and a crown region of the outer-layer.

17. The protective helmet of claim 16 , wherein:

the inner-layer has a plurality of channels, said channels extending upward from a lowermost edge of the inner-layer and completely through the inner-layer whereby the inner-layer is segmented;

the middle-layer has a plurality of channels extending completely through the middle-layer, and wherein at least two of the plurality of channels in the middle-layer are substantially aligned with at least two of the plurality of channels in the inner-layer; and

the outer-layer has a plurality of channels extending completely through the outer-layer.

18. The protective helmet of claim 16 , wherein a lowermost edge of the middle-layer resides above an extent of a lowermost edge of the outer-layer.

19. The protective helmet of claim 18 , wherein: (i) an extent of the middle-layer is removed from a front region of the middle-layer to form an opening in said middle-layer, wherein said removed portion does not form one of the channels in the middle-layer, (ii) a linear extent of a lowermost edge of the middle-layer is positioned in the front region of the multi-layer liner assembly, and (iii) a non-linear extent of the lowermost edge of the middle-layer is positioned in a side region of the multi-layer liner assembly.

20. The protective helmet of claim 19 , wherein middle-layer has a thickness that is less than 4 millimeters and the inner-layer has a non-uniform thickness that is less than 25 millimeters.

21. The protective helmet of claim 20 , wherein the cumulative thickness of both the outer-layer and the middle-layer is less than or equal to 45 mm.

22. The protective helmet of claim 20 , wherein the outer-layer comprises a high-energy management material.