Protective helmet with liner assembly

1. A protective helmet comprising:

an outer shell;

a liner assembly received in the outer shell and connected to the outer shell, the liner assembly defining a front portion configured to overlay a front of a head of a wearer, a rear portion configured to overlay a rear of the head of the wearer, a top portion configured to overlay a top of the head of the wearer, and two opposed side portions each configured to overlay a respective side of the head of the wearer;

wherein each of the front, rear, side and top portions includes one or more zones where the liner assembly includes a plurality of overlapping layers, each of the layers being made from one of first, second, third and fourth materials, where the first material has a greater density than that of the second, the third and the fourth materials, the second material has a greater density than that of the third and the fourth materials, and the third material has a greater density than that of the fourth material, and:

the one or more zones of the front portion includes one or more of zones F 1 , F 2 and F 3 , wherein

the zone F 1 includes a layer of the second material of at least 3.2 millimeters (mm) thickness, a layer of the third material of at least 4.8 mm thickness, a layer of the second material of at least 8 mm thickness, and a layer of the third material of at least 6.4 mm thickness,

the zone F 2 includes a layer of the second material of at least 8 millimeters (mm) thickness, a layer of the third material of at least 16 mm thickness, and a layer of the fourth material of at least 6.4 mm thickness, and

the zone F 3 includes a layer of the second material of at least 11.2 millimeters (mm) thickness, and a layer of the third material of at least 6.4 mm thickness;

the one or more zones of the rear portion includes one or more of zones R 1 and R 2 , wherein

the zone R 1 includes a layer of the second material of at least 6.4 millimeters (mm) thickness, a layer of the first material of at least 1.6 mm thickness, a layer of the second material of at least 12.8 mm thickness, and a layer of the fourth material of at least 3.2 mm thickness, and

the zone R 2 includes a layer of the second material of at least 6.4 millimeters (mm) thickness, a layer of the first material of at least 1.6 mm thickness, a layer of the third material of at least 9.6 mm thickness, and a layer of the fourth material of at least 6.4 mm thickness;

the one or more zones of the side portions includes at one or more of zones S 1 and S 2 , wherein

the zone S 1 includes a layer of the second material of at least 4.8 millimeters (mm) thickness, a layer of the first material of at least 3.2 mm thickness, a layer of the third material of at least 8 mm thickness, and a layer of the fourth material of at least 6.4 mm thickness, and

the zone S 2 includes a layer of the second material of at least 3.2 millimeters (mm) thickness, and a layer of the third material of at least 18.4 mm thickness; and

the one or more zones of the top portion includes one or more of zones T 1 and T 2 , wherein

the zone T 1 includes a layer of the second material of at least 3.2 millimeters (mm) thickness, and a layer of the third material of at least 18.4 mm thickness, and

the zone T 2 includes a layer of the second material of at least 11.2 millimeters (mm) thickness, and a layer of the third material of at least 6.4 mm thickness.

2. The protective helmet as defined in claim 1 , wherein the front portion includes all of the zones F 1 , the zone F 2 and the zone F 3 .

3. The protective helmet as defined in claim 1 , wherein the rear portion includes the zones R 1 and the zone R 2 .

4. The protective helmet as defined in claim 1 , wherein the side portions include the zones S 1 and the zone S 2 .

5. The protective helmet as defined in claim 1 , wherein the top portion includes the zones T 1 and the zone T 2 .

6. The protective helmet as defined in claim 1 , wherein

in the zone F 1 :

the layer of the at least 3.2 mm thickness is at least 4 mm thick, the layer of the at least 4.8 mm thickness is at least 6 mm thick, the layer of the at least 8 mm thickness is at least 10 mm thick, and the layer of the at least 6.4 mm thickness is at least 8 mm thick;

in the zone F 2 :

the layer of the at least 8 mm thickness is at least 10 mm thick, the layer of the at least 16 mm thickness is at least 20 mm thick, and the layer of the at least 6.4 mm thickness is at least 8 mm thick;

in the zone F 3 :

the layer of the at least 11.2 mm thickness is at least 14 mm thick, and the layer of the at least 6.4 mm thickness is at least 8 mm thick;

in the zone R 1 :

the layer of the at least 6.4 mm thickness is at least 8 mm thick, the layer of the at least 1.6 mm thickness is at least 2 mm thick, the layer of the at least 12.8 mm thickness is at least 16 mm thick, and the layer of the at least 4 mm thickness is at least 8 mm thick;

in the zone R 2 :

the layer of the at least 6.4 mm thickness is at least 8 mm thick, the layer of the at least 1.6 mm thickness is at least 2 mm thick, the layer of the at least 9.6 mm thickness is at least 12 mm thick, and the layer of the at least 6.4 mm thickness is at least 8 mm thick;

in the zone S 1 :

the layer of the at least 4.8 mm thickness is at least 6 mm thick, the layer of the at least 3.2 mm thickness is at least 4 mm thick, the layer of the at least 8 mm thickness is at least 10 mm thick, and the layer of the at least 6.4 mm thickness is at least 8 mm thick;

in the zone S 2 :

the layer of the at least 3.2 mm thickness is at least 4 mm thick, and the layer of the at least 18.4 mm thickness is at least 23 mm thick;

in the zone T 1 :

the layer of the at least 3.2 mm thickness is at least 4 mm thick, and the layer of the at least 18.4 mm thickness is at least 23 mm thick; and

in the zone T 2 :

the layer of the at least 11.2 mm thickness is at least 14 mm thick, and the layer of the at least 6.4 mm thickness is at least 8 mm thick.

7. The protective helmet as defined in claim 1 , wherein the first material has a greater hardness than that of the second, third and fourth materials, the second material has a greater hardness than that of the third and fourth materials, and the third material has a greater hardness than that of the fourth material.

8. The protective helmet as defined in claim 1 , wherein the first, second, and third materials are vinyl nitrile foam, and the fourth material is Ethylene-vinyl acetate (EVA) foam.

9. The protective helmet as defined in claim 1 , wherein, the density of the first material is in a range of 0.17 to 0.21 (g/cm3), the density of the second material is in a range of 0.11 to 0.14 (g/cm3), the density of the third material is in a range of 0.09 to 0.12 (g/cm3), and the density of the fourth materials is in a range of 0.09 to 0.12 (g/cm3).

10. The protective helmet as defined in claim 1 , wherein the hardness of the first material is in a range of 75 to 95 (Shore 00), the hardness of the second material is in a range of 65 to 85 (Shore 00), the hardness of the third material is in a range of 55 to 75 (Shore 00), and the hardness of the fourth material is in a range of 35 to 75 (Shore 00).

11. A protective helmet comprising:

an outer shell;

a liner assembly received in the outer shell and connected to the outer shell, the liner assembly defining a front portion configured to overlay a front of a head of a wearer, a rear portion configured to overlay a rear of the head of the wearer, a top portion configured to overlay a top of the head of the wearer, and two opposed side portions each configured to overlay a respective side of the head of the wearer;

wherein each of the front, rear, side and top portions includes a zone where the liner assembly includes a plurality of overlapping layers, each of the layers being made from one of first, second, third and fourth materials, where the first material has a greater hardness than that of the second, third and fourth materials, the second material has a greater hardness than that of the third and fourth materials, and the third material has a greater hardness than that of the fourth material, and:

the one zone of the front portion includes one or more of zones F 1 , F 2 and F 3 , wherein

the zone F 1 including a layer of the second material of at least 3.2 millimeters (mm) thickness, a layer of the third material of at least 4.8 mm thickness, a layer of the second material of at least 8 mm thickness, and a layer of the third material of at least 6.4 mm thickness,

the zone F 2 including a layer of the second material of at least 8 millimeters (mm) thickness, a layer of the third material of at least 16 mm thickness, and a layer of the fourth material of at least 6.4 mm thickness, and

the zone F 3 including a layer of the second material of at least 11.2 millimeters (mm) thickness, and a layer of the third material of at least 6.4 mm thickness;

the zone of the rear portion includes one or more of zones R 1 and R 2 , wherein

the zone R 1 including a layer of the second material of at least 6.4 millimeters (mm) thickness, a layer of the first material of at least 1.6 mm thickness, a layer of the second material of at least 12.8 mm thickness, and a layer of the fourth material of at least 3.2 mm thickness, and

the zone R 2 including a layer of the second material of at least 6.4 millimeters (mm) thickness, a layer of the first material of at least 1.6 mm thickness, a layer of the third material of at least 9.6 mm thickness, and a layer of the fourth material of at least 6.4 mm thickness;

the zone of the side portions includes one or more of zones S 1 and S 2 , wherein

the zone S 1 including a layer of the second material of at least 4.8 millimeters (mm) thickness, a layer of the first material of at least 3.2 mm thickness, a layer of the third material of at least 8 mm thickness, and a layer of the fourth material of at least 6.4 mm thickness, and

the zone S 2 including a layer of the second material of at least 3.2 millimeters (mm) thickness, and a layer of the third material of at least 18.4 mm thickness; and

the zone of the top portion includes one or more of zones T 1 and T 2 , wherein

the zone T 1 including a layer of the second material of at least 3.2 millimeters (mm) thickness, and a layer of the third material of at least 18.4 mm thickness, and

the zone T 2 including a layer of the second material of at least 11.2 millimeters (mm) thickness, and a layer of the third material of at least 6.4 mm thickness.

12. The protective helmet as defined in claim 11 , wherein the liner assembly includes all of the zones F 1 , F 2 , F 3 , R 1 , R 2 , S 1 , S 2 , T 1 and T 2 .

13. The protective helmet as defined in claim 11 , wherein:

the density of the first material is in a range of 0.17 to 0.21 (g/cm3), the density of the second material is in a range of 0.11 to 0.14 (g/cm3), the density of the third material is in a range of 0.09 to 0.12 (g/cm3), and the density of the fourth material is in a range of 0.09 to 0.12 (g/cm3); and

the hardness of the first material is in a range of 75 to 95 (Shore 00), the hardness of the second material is in a range of 65 to 85 (Shore 00), the hardness of the third material is in a range of 55 to 75 (Shore 00), and the hardness of the fourth material is in a range of 35 to 75 (Shore 00).