A football helmet with shell, faceguard, padding and comfort liner system, has replaceable nose bumpers for connecting a top center of the faceguard to the shell, button and keyhole connectors connecting the liner to an inner surface of the padding and T-nut connectors for connecting the padding to an inner surface of the shell. Front portions of the comfort liner have harder foam cushions than other portions of the liner to improve impact absorption. Selected areas of the padding system contain pads with inner and outer molded thermoplastic urethane parts of different durometer, each including a sheet with plural alternating hollow protrusions. The faceguard has an upper bar with raised ends above a lower edge of the front portion of the shell that form a face opening and on either side of the nose bumper.
1. A helmet comprising:
a rigid plastic shell adapted to cover the head of a wearer, the rigid shell having an inner surface;
a plurality of pads removably attached to the inner surface for absorbing impact;
each of the plurality of pads having an outer part of a first urethane having a first durometer and an inner part formed of urethane having a second durometer, the inner part and outer part separated such that a space is formed therebetween and is open around a perimeter of the pad;
the inner part comprising a sheet having hollow protrusions extending toward the outer part and integrally formed with the sheet from which they extend, each protrusion having a base and a peak wherein the base is larger than the peak;
the outer part comprising a sheet having hollow protrusions extending toward the inner part and integrally formed with the sheet from which they extend, each protrusion having a base and a peak wherein the base is larger than the peak;
wherein at least one peak of a protrusion of the inner part is fused to the sheet of the outer part and at least one peak of a protrusion of the outer part is fused to the sheet of the inner part;
the protrusions of the inner part alternating with the protrusions of the outer part to form an impact absorbing pattern of alternating protrusions in the space between the sheets; and
a comfort liner removably attached to the sheet of the inner part of at least one of the plurality of pads.
2. The helmet of claim 1 , wherein the first durometer is between about 80 and 95 Shore-A and the second durometer is between about 90 and 95 Shore-A.
3. The helmet of claim 1 , wherein at least one of the plurality of pads has, in the sheet of its inner part, a keyhole with a large diameter portion and a small diameter portion communicating with the large diameter portion.
4. The helmet of claim 3 , wherein the comfort liner has a button comprising a stem for engaging the keyhole, the button having a diameter smaller than the large diameter portion of the keyhole, and the stem having a diameter for being received in a the small diameter portion of the keyhole, so that the button is adapted to be removably trapped in the keyhole.
5. The helmet of claim 1 , further comprising a faceguard comprising a cage of metal bars having a pair of side bar parts connected by side connectors to respective side portions of the shell, and an upper portion having a center bar part connected by a nose bumper to the front portion of the shell, the upper portion of the faceguard including a pair of side bar parts that are each bent upwardly with respect to the center bar part by at least a multiple of a diameter of the center bar part, and then extend downwardly toward each respective side bar part for create a raised eyebrow area on either side of the front portion of the rigid shell to dissipate impacts at the front portion of the shell.
6. The helmet of claim 1 wherein the comfort liner comprises an assembly of a plurality of triangular foam members and a substantially quadrangular foam member positioned to engage the forehead of the wearer.
7. The helmet of claim 6 wherein the quadrangular foam member is made of a harder foam then the triangular foam members.
8. The helmet of claim 7 wherein the quadrangular foam member has between about 3 and 10 more Shore “O” durometer hardness than the triangular foam members.
9. The helmet of claim 1 wherein the plurality of pads comprises a front pad removably attached at a front portion of the shell, a crown pad removably attached at a crown portion of the shell, a pair of side pads removably attached at respective side portions of the shell; and a back pad removably attached at a back portion of the shell.
10. The helmet of claim 1 wherein upon an impact to an outer surface of the rigid shell and a resulting relative movement of the helmet with respect to the head of the wearer, the small diameter peaks of the outer part of the pads in an area of the impact, having the first lower durometer, collapse more easily than the peaks of the inner part of the pad in the area of impact, to dissipate the impact with reduced pressure on the head of the wearer.
11. A helmet pad comprising:
an outer part of a first urethane having a first durometer and an inner part formed of urethane having a second durometer, the inner part and outer part separated such that a space is formed therebetween and open around a perimeter;
the inner part comprising a sheet having hollow protrusions extending toward the outer part and integrally formed with the sheet from which they extend, each protrusion having a base and a peak wherein the base is larger than the peak;
the outer part comprising a sheet having hollow protrusions extending toward the inner part and integrally formed with the sheet from which they extend, each protrusion having a base and a peak wherein the base is larger than the peak;
wherein the peak of the protrusion of the inner part is fused to the sheet of the outer part;
wherein the peak of the protrusion of the outer part is fused to the sheet of the inner part; and
the protrusions of the inner part alternating with the protrusions of the outer part sheet to form an impact absorbing pattern of alternating protrusions in the space between the sheets.
12. The helmet pad of claim 11 , wherein the first durometer is between about 80 and 95 Shore-A and the second durometer is between about 90 and 95 Shore-A.