TECHNICAL FIELD

[001] The technical field relates generally to impact absorbing structures, and more specifically to cushion pads in athletic gear.

BACKGROUND

[002] Contact sports, and more specifically single-contact sports and multi-contact sports, generally involve collisions and, in some cases, repeated collisions. Nonlimitative examples of multi-contact sports include American football and hockey. Repeated collisions, especially proximate the head, the neck and/or the shoulder regions can result in serious injuries. While impact absorbing structures for use in athletic gear, such as helmets, have evolved greatly over the years in an attempt to provide optimum protection to the user, there is still a general need for improvements.

SUMMARY

[003] In accordance with one aspect, there is provided a cushion pad for providing protection to equipment. The cushion pad includes an internal structure, a bladder, and a valve. The internal structure has shock-absorbing properties. The bladder encloses the internal structure to define an internal volume of the internal structure. The valve passes through the bladder and is in fluid communication with the internal structure. The valve is configured to allow a passage of an airflow into or out of the internal structure, such that an internal pressure within the internal volume of the internal structure varies when an impact force is applied to the cushion pad.

[004] In some embodiments, the valve is configured to control airflow out and resulting pressure inside of the internal structure proportional to the impact speed. [005] In some embodiments, the valve is configured to control airflow into the internal structure resulting in a delayed bladder shape recovery with limited impact spring-back.

[006] In some embodiments, the cushion pad further includes a vent in fluid communication with the internal structure.

[007] In some embodiments, the cushion pad further includes support posts positioned in a bottom portion of the cushion pad.

[008] In some embodiments, the bladder is mechanically independent from the internal structure.

[009] In accordance with one aspect, there is provided a helmet including an outer shell, a support structure and a plurality of cushion pads. The outer shell defines a cavity for receiving a head of a person. The support structure is coupled to the outer shell and positioned within the cavity. The support structure includes a web of support material positioned in a spaced-apart relation relative to the outer shell and defines a plurality of openings. The plurality of cushion pads is similar to the embodiments herein described and is provided within respective openings of the web of support material. The plurality of cushion pads forms a liner of the helmet.

[0010] In some embodiments, the support structure is a head-shaped sling.

[0011] In some embodiments, the support structure is a planar sling.

[0012] In accordance with one aspect, there is provided a helmet including an outer shell defining a cavity for receiving a head of a person; a support structure coupled to the outer shell and positioned within the cavity, the support structure including a web of support material positioned in a spaced-apart relation relative to the outer shell; and cushion-engaging members extending from the web of support material; and a plurality of cushion pads as defined herein, locked to the cushion-engaging members, the plurality of cushion pads forming a liner of the helmet.

[0013] In some embodiments, the support structure is a head-shaped sling.

[0014] In some embodiments, the support structure is a planar sling.

[0015] In accordance with one aspect, there is provided a cushion pad for providing protection to equipment. The cushion pad includes an internal structure and a bladder. The internal structure has shock-absorbing properties, and the bladder encloses the internal structure.

[0016] In accordance with one aspect, there is provided a method for manufacturing a cushion pad for providing protection to equipment. The method includes additively forming an internal structure and a bladder of the cushion pad, wherein said additively forming the internal structure and the bladder includes alternating between the internal structure and the bladder. In some embodiments, the bladder pad should be connected to the internal structure in way that will not interfere with its ability to compress and deform.

[0017] In some embodiments, the bladder is mechanically independent from the internal structure.

[0018] Other features and advantages of the present description will become more apparent upon reading of the following non-restrictive description of specific embodiments thereof, given by way of example only with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 shows a cushion pad according to one embodiment.

[0020] Figure 2 illustrates a cushion pad with a valve according to one embodiment. [0021] Figures 3A-B show a diagram of the mechanical behavior of a cushion pad with an opening, according to one embodiment.

[0022] Figures 4A-B show a cushion pad having at least one aperture for providing fluid communication between top and bottom surfaces thereof, according to one embodiment.

[0023] Figures 5 to 8 show a helmet including an array of cushion pads, according to one embodiment.

[0024] Figures 9 to 11 show a placeholder adapted to support cushion pads within the cavity along the inner surface of the outer shell, according to one embodiment.

[0025] Figures 12A-D illustrate different possible layering sequences for a cushion pad, according to one embodiment.

[0026] Figure 13 shows a cushion pad, in accordance with one embodiment.

[0027] Figure 14 is a top perspective view of the cushion pad of Figure 13.

[0028] Figures 15A-C illustrate the cooperation between a sling, an outer shell and a cushion pad, according to one embodiment.

[0029] Figure 16 shows a planar sling mechanically coupled to a plurality of cushion pads, according to one embodiment.

[0030] Figure 17 shows the cushion pads of Figure 16.

DETAILED DESCRIPTION

[0031] As will be explained below in relation to various embodiments, the present disclosure describes devices, systems, and methods for forming protective gear, such as padding for use in various equipment and/or systems. The padding can be used as part of a helmet to improve shock absorption and/or dissipation, among other advantages. [0032] More particularly, the present disclosure relates to a cushion pad (sometimes referred to as an “impact absorbing/dissipating structure”) for use in athletic gear, for example for providing protection to equipment and to the user wearing the equipment. The cushion pad that will be herein described generally includes at least an internal structure and a bladder enclosing the internal structure. In some embodiments, the cushion pad may be used as a liner in helmets, or part of a piece of equipment to absorb and/or dissipate the energy associated with an impact. In some embodiments, the cushion pad may be used in pads to provide protection to knees, elbows and/other portions of the human body. In some embodiments, the cushion pad may be mounted on relatively hard surfaces, such as walls (or portion(s) thereof), as a safety measure against potential injury due to impact. In some embodiments, the cushion pad may be used to protect items such as camera, drones, laboratory equipment, and many other relatively fragile items. In some embodiments, the cushion pad may have progressive or tunable stiffening, improved impact dampening, improved airflow circulation, and/or improved manufacturing process.

[0033] In some embodiments, the cushion pad may be used in a helmet, such as a football helmet. In these embodiments, the helmet may include a plurality of cushion pads (simply referred to as “cushion pads”), and the cushion pads may be positioned in a predetermined configuration using a placeholder secured to an inner surface of the helmet. The placeholder can be shaped and adapted to the helmet to hold the cushion pads in a respective configuration along an interior or an internal portion of the helmet. The placeholder, and corresponding parts, defines a plurality of apertures in which the cushion pads can be positioned. The cushion pads may be made in a single block and adapted to the shape and size of the helmet. Alternatively, the cushion pad may be made as a plurality of units, each unit configured to be received in a particular position on the helmet. In such a configuration, each unit may have corresponding properties, such as, for example and without being limitative, stiffness, as a function of the desired behavior of the unit at that position on the helmet. Of note, the cushion pads each have shock absorbing properties provided by the internal structure forming the same, as it will be described in greater detail below. In some embodiments, the cushion pad may be formed in one block, but may have different internal structures depending on the position of the corresponding internal structure to provide different mechanical properties at different positions of the helmet. The design and positioning of the internal structure may be optimized depending on the targeted application.

[0034] In some embodiments, the internal structure defines a predetermined or a substantially organized lattice, and so may be referred to as an internal lattice structure. The internal structure may be embodied by structures of different shape(s), size and/or configuration, such as, for example and without being limitative, cubic structures, honeycomb structures, structures made from minimal surfaces, gyroid structures, mesh structures, and many others, including combinations thereof. The internal structure may include a periodic pattern, a semiperiodic pattern, an aperiodic pattern, and any combinations thereof. In some embodiments, the internal structure includes a combination of “lattice types”, each lattice type having a corresponding configuration or geometry. An internal structure including such a combination of lattices type may be useful when the desired or targeted properties of the cushion pad are dependent on the positioning of the cushion pad, which may be the case in a helmet or other equipment. In some embodiments, and as it will be described in greater detail below, the cushion pad, or at least a portion thereof, may be produced using additive manufacturing techniques. Of course, other manufacturing methods could also be used.

[0035] With reference to Figure 1 , a cushion pad 10 according to a possible embodiment is illustrated. The cushion pad 10 includes an internal structure 30 having shock-absorbing properties and a bladder 14 enclosing the internal structure 30 to define an internal volume of the internal structure 30. As will be described further below, the cushion pad 10 can be integrated as part of various devices and/or systems to provide protection, and more specifically mechanical protection (e.g., shock absorbance) to the device, the system and/or the person(s) using or operating the device or system. In some embodiments, the cushion pad 10 is integrated into a helmet liner to provide support between a helmet shell and an interior surface of the helmet facing a head of a user.

[0036] Still referring to Figure 1 , there is shown an internal structure 30 according to one embodiment. The internal structure 30 may have any suitable overall geometry and/or size adapted to provide protection to a user when the cushion pad is implemented in a helmet or the like. In Figure 1 , the internal structure 30 includes a lattice including a plurality of nodes 32 (or “points”), connected one to another by strut members 34 to define a plurality of cells 36. The cells 36 may have a substantially cubic shape. Of course, the cells 36 may have any other shapes, and each cell 36 may be similar one from each other, or may alternative be different one from each other. In some embodiments, the internal structure 30 of the cushion pad may be similar to at least one of the embodiments described in US 63/203, 134, the content of which is herein incorporated by reference in its entirety.

[0037] The bladder 14 is adapted, positioned and sized to surround and enclose the internal structure 30. The bladder 14 may have any suitable overall geometry that allows surrounding and enclosing the internal structure 30. In the embodiment depicted in Figure 1 , the bladder 14 is defined by a plurality of surfaces, collectively forming a continuous outer layer. More specifically, the bladder 14 according to this embodiment includes a top horizontal surface, an angled top surface 16, two opposing angled side surfaces 20, a side surface 18 connecting the angled top surface 16 to a topmost one of the two opposing angled side surfaces, and a bottommost one of the two opposing angled side surfaces 20 connecting to a bottom wall 24 of the cushion pad 10. As illustrated, the bottom wall 24 may be connected by a plurality of support posts 26 to the bottom surface 28 of the cushion pad 10. Of course, the general shape of the cushion pad 10 may be different and may be embodied, for example, and without being limitative, by a rectangle or any other multi-sided polygon, as it will be explained in greater detail below. [0038] The internal structure 30 of the cushion pad 10 provides resiliency to the cushion pad 10, so that the cushion pad 10 can absorb at least a portion of the energy associated with the impact force exerted on or applied to the cushion pad 10, or the device or system to which the cushion pad 10 is mounted. Of note, the deformation of the cushion pad 10 is generally reversible, but not necessarily instantaneous (i.e., the cushion pad may remain in a compressed configuration for a given period before going back to its original uncompressed configuration, or could alternatively slowly return back to its original uncompressed configuration). For example, the cushion pad 10 may be in a “deformed” or “compressed” configuration when a force is applied to the cushion pad or when energy is absorbed by the cushion pad, and the cushion pad may be in a “relaxed”, “original” or “uncompressed” configuration when no force is applied to the cushion pad or after the energy is released from the cushion pad. As such, the cushion pad 10 may be deformed back and forth between an initial configuration or state, and a compressed configuration or state. The cushion pad 10 may return to its initial configuration once the force of the impact is removed, or when the energy associated with the force of the impact has been released or dissipated. Otherwise, the rate of decompression of the cushion pad 10 may be controlled using a valve or any similar mechanical components, as it will be described with greater detail below. In some embodiments, the support posts 26 may provide greater rigidity to the cushion pad 10. In the illustrated embodiment, the cushion 10 comprises a wedge 40 on each side shaped by the two opposing angled side surfaces 20. The wedge 40 provides a location where the cushion pad 10 may be engaged to be held in place by a corresponding support structure. In some embodiments, the wedge 40 may be defined by at least two surfaces of the bladder 14, for example and without being limitative the two angled surfaces 20. In some embodiments, the cushion pad 10 may be clipped to the corresponding support structure through the wedge 40. In some embodiments, the cushion pad 10 may be provided without the wedge 40. [0039] The internal structure 30 has mechanical properties, such as shockabsorbing properties and stiffness, which are associated with how the cushion pad will react or respond to an impact (i.e., absorb and/or dissipate the energy associated with the impact). The stiffness of the cushion pad 10 may be adjusted depending on the anticipated or expected parameters or properties of the impact, which may for example include impact force, direction of the impact, and/or frequency of the impact. For example, the stiffness of the cushion pad 10 may be selected by selecting the density of the internal structure 30, such as by increasing the thickness of the strut members 34, reducing the size of the cells 36, changing the orientation of the cells 36 if the cells 36 have a non-symmetric shape, or by selection of a desired material for the internal structure 30 (or portion(s) thereof). In some embodiments, the internal structure 30 may comprise more than one type of lattice structure, such that, for example, the internal structure 30 comprises a combination of non-symmetric, honeycomb and/or cubic cells so that the internal structure 30 within the cushion pad 10 has a non-uniform stiffness depending on the direction of impact.

[0040] In some embodiments, each cell 36 is substantially aligned one with each other along two axes, i.e., subsequent or neighbouring cells 36 are aligned along the vertical axis V and the horizontal axis H. In some embodiments, at least some adjacent layers, rows or columns of cells 36 may be offset relative to each other or may be at an angle relative to the vertical axis V and/or the horizontal axis H. In some embodiments, the cells 36 may be angularly offset relative to one another, so that, for example, one row of cells 36 is aligned along the horizontal axis H while an adjacent row of cells 36 is at an angle to the horizontal axis H. In some embodiments, all the cells 36 may be disposed at an angle with respect to the horizontal axis H and/or the vertical axis V.

[0041] With reference to Figure 2, there is shown a cushion pad 80 in accordance with another embodiment. The cushion pad 80 has an internal structure similar to the internal structure of cushion pad 10. The cushion pad 80 is adapted for resiliently absorbing the energy caused or associated with the impact. As illustrated in Figure 2, the cushion pad 80 has a top surface 82, sides 84, and a bottom surface, collectively defining a bladder enclosing the internal structure of the cushion pad. The sides 84 extend downwardly from the top surface 82 and towards the bottom surface. In the illustrated embodiment, there are a total of six angled outwardly extending faces 86 which extend downwardly from the top surface 82. The outwardly extending faces 86 connect to inwardly extending faces 88 which, similar to the cushion pad 10, terminate in a wedge 90 having a topmost and bottommost surface. A vertical surface 92 connects a bottommost surface of the wedge 90 to the bottom surface of the cushion pad 80, the various surfaces described herein together making each of the respective sides 84 of the cushion pad 80. Although six sides 84 are shown in the illustrated embodiment, the cushion pad 80 may have any number of sides, such as four, five or another suitable number. In some embodiments, the cushion pad 80 may have any other shape and may comprise curved sides 84 in addition to or in place of straight surfaces. As illustrated, the cushion pad 80 is sealed by the bladder. The cushion pad 80 includes an opening 94 for expelling or drawing in air in the internal structure of the cushion pad 80. The opening 94 is in fluid communication with an exterior of the cushion pad 80 (the “environment”) and the internal structure, so that a fluid (e.g., air) may flow between cells of the internal structure and the exterior of the cushion pad 80.

[0042] As shown in the illustrated embodiment, the opening 94 may comprise a valve 98. The valve 98 is configured or adapted to control the fluid flow between the exterior and the internal structure 30 of the cushion pad 80. For example, the valve 98 can be a one-way valve to only allow fluid flow in one direction. Alternatively, the valve 98 can control the pressure at which fluid can flow between the exterior and the internal structure, which can be associated with the compression and/or decompression rate (/.e., the rate at which the cushion pad goes from an original uncompressed configuration towards a compressed configuration, or vice versa). In this embodiment, the valve 98 can control the amount of pressure that builds within the cushion pad 80, for example as a result of a sudden impact. Accordingly, stiffness of the cushion pad 80 can be controlled with a combination of the internal structure (and mechanical properties thereof) and the air within the lattice structure. For example, if there is a low impact speed or velocity on the cushion pad 80 causing little deformation, the valve 98 may permit fluid to exit the cushion pad 80 smoothly and with little or no resistance. If there is a high impact speed on the cushion pad causing significant deformation, the valve 98 may prevent fluid from exiting the cushion pad or to provide substantial resistance thereto. In such an embodiment, the valve 98 may permit the cushion pad to provide additional cushioning or protection during impact at high speed. Although only one opening 94 is shown in the illustrated embodiment, and the opening 94 comprises the valve 98, it is envisaged that there may instead be multiple openings. Some of the multiple openings may comprise corresponding valves, while others may simply be vents which do not control the flow of air. In some embodiments, all of the multiple openings can comprise valves. In some embodiments, all of the multiple openings may be vents.

[0043] In some embodiments, the cushion pad may comprise a plurality of valves to allow a control of the air inlet and outlet by different or independent valves.

[0044] With reference to Figures 3a and 3b, in accordance with some embodiments, there is shown a diagram of the mechanical behavior of the cushion pad 80 with the opening 94. The cushion pad 80 deforms under impact, as shown in Figure 3a, resulting in an increase in air pressure which exits through the opening. Once the impact is removed, the cushion pad 80 resiliently returns to its original form, drawing air from the exterior. In one embodiment, the opening 94 comprises a valve to control airflow in and out of the cushion pad 80. Controlling airflow out of the cushion pad 80 has the benefits previously described, such as providing additional cushioning with a variable stiffness depending on impact speed or velocity. In one embodiment, airflow into the cushion pad 80 may also be controlled. Control of the rate at which fluid flows into the cushion pad allows for control of the rate at which the cushion pad 80 returns to its original form. For example, fluid may be restricted from entering the cushion pad 80, slowing the rate at which the cushion pad 80 regains its original form. This delayed form recovery reduces spring-back of the cushion pad 80 post impact, reducing its restitution coefficient. The restitution coefficient e is defined as the ratio of the velocity of an object after an impact to its velocity prior to the impact in the normal direction:

[0045] Accordingly, if an object had an entirely elastic collision, it would have a restitution coefficient of 1 , whereas an entirely inelastic collision would have a restitution coefficient of 0. Reducing the restitution coefficient of the cushion pad 80 provides the benefit of reducing its spring-back so that the cushion pad 80 does not exert a sudden force after the impact in the direction of form recovery.

[0046] With reference to Figures 4a and 4b, in accordance with some embodiments, there is provided cushion pads 100, 150 having at least one aperture for providing fluid communication between top and bottom surfaces thereof. The cushion pad 100 comprises three apertures 102, 102a, of which aperture 102a is shown in cross-section, though it is identical to the other two apertures 102. In some embodiments, each aperture 102 and 102a may have a different profile, including dimensions and geometrical properties. As illustrated in Figures 4A-B, the apertures 102, 102a extend from a top surface 104 of the cushion pad 100 to a bottom surface 106. The cushion pad 100 is similar to the cushion pad 10 in that it also comprises a lattice structure (not shown) for resi I iently absorbing impact applied to the cushion pad 100. The apertures 102, 102a allow fluid communication between the top surface 104 and the bottom surface 106. This may be particularly beneficial when the cushion pad 100 is placed in a device, such as a helmet, where breathability is a desired attribute, or when a circulation of an airflow within the helmet can be required. The apertures 102, 102a may permit sweat to evaporate or air to circulate therethrough and, for example, exit through a corresponding slot in the helmet into the ambient environment, which may help managing heat emanating from the user.

[0047] With reference to Figure 4b, another cushion pad 150 similar to the cushion pad 100 is illustrated. The cushion pad 150 comprises a lattice structure 152 and an aperture 154. The aperture 154 is similar to apertures 102, 102a, and provides fluid communication between a top surface 156 of the cushion pad 150 to a bottom surface 158. The aperture 154 includes a chamfered top portion 160 and a chamfered bottom portion 162. In the illustrated embodiment, the bottom portion 162 has a smaller chamfer compared to the top portion 160. Alternatively, the bottom portion 162 may have a larger chamfer than the top portion 160, or they may be the same size. The chamfered top portion 160 and bottom portion 162 increase the area from each of the top surface 156 or bottom surface 158 that is in fluid communication with the other one of the top surface 156 or bottom surface 158 while maintaining the diameter of the aperture. In some embodiments, each aperture may be in fluid communication with a greater surface area on each, or at least one of, the top surface 156 and the bottom surface 158 to improve breathability. It is understood that the apertures illustrated in Figures 4a and 4b could also be added to the previous cushion pads 10, 80.

[0048] In some embodiments, and as illustrated in Figure 13, the internal structure of the cushion pad 10, 80, 100, 150 may be embodied by a hexa-octo lattice structure.

[0049] With reference to Figures 5 to 8, in some embodiments, the cushion pads 10, 80, 100, 150 are part of an array of cushion pads forming a liner 202 for a helmet 200. In the illustrated embodiments, the helmet 200 corresponds to a football helmet, although it should be noted that other helmets and/or other types of equipment can include the liner 202 formed of a plurality of cushion pads 10, 80, 100, 150. The helmet 200 includes an outer shell 204 having an outer surface 206 and an inner surface 208, where the inner surface 208 defines a cavity 210 of the helmet 200 for receiving the head of a user. The outer shell 204 also defines a front opening 212 enabling the person to see through, with the helmet 200 being provided with a faceguard 214 connected to the outer shell 204 for at least partially protecting the wearer’s face (e.g., nose, mouth, eyes, etc.). The outer shell 204 further includes a bottom opening 216 enabling a person’s head to engage the cavity 210 from below. It should be noted that, in other embodiments, the helmet 200 can be provided with a visor (e.g., instead of, or in addition to the facemask) coupled to the outer shell 204 and being pivotable between open and closed positions for respectively opening and closing the front opening 212.

[0050] The cushion pads 10, 80, 100, 150 may be provided along the inner surface 208 of the outer shell 204 such that the cushion pads are positioned between the user’s head and the outer shell 204 when wearing the helmet 200. It is appreciated that the cushion pads can have respective shapes, sizes, configurations or a combination thereof, based on their position along the inner surface 208, among others. In the embodiment illustrated in Figure 8, the cushion pads 10, 80, 100, 150 can be installed within the cavity 210 along an inner layer 218 and an outer layer 220. In one embodiment, the inner layer 218 and the outer layer 220 each have their respective properties, which may be, for example, and without being limitative, the lattice structure (e.g., honeycomb or cubic), presence or lack of a valve, use of a material to provide a desired stiffness, and many other. The combination of the inner layer 218 and outer layer 220 may therefore confer improved shock absorption and/or comfort. The inner layer 218 and outer layer 220 may as in the illustrated embodiment, be generally shaped to conform to the head of the user.

[0051] As seen in Figures 9 to 11 , in addition to Figures 5 to 8, the helmet 200 can include a placeholder 222 adapted to support the cushion pads 10, 80, 100, 150 within the cavity 210 along the inner surface 208 of the outer shell 204. The placeholder 222 can be shaped and adapted to support each cushion pad individually, i.e. , independently from the other cushion pads. In this embodiment, the cushion pads 10, 80, 100, 150 can be removably installed on the placeholder 222, thereby enabling the removal of one or more cushion pads for maintenance, replacement, or repositioning, among others. As will be described further below, the placeholder 222 can be removably coupled to the outer shell 204 and is positioned so as to be spaced from a head of the person wearing the helmet 200 and spaced from the inner surface 208.

[0052] In some embodiments, the placeholder 222 can include a sling 224 connectable to the outer shell 204 and being shaped and sized to support the cushion pads 10, 80, 100, 150. More specifically, the sling 224 can be made of a web of material 226 defining a plurality of openings 228 for receiving the cushion pads. In this embodiment, the sling 224 includes a generally continuous edge 230, and each one of the openings 228 is complementarily shaped relative to one or more of the cushion pads 10, 80, 100, 150 such that each cushion pad fits snugly within the corresponding opening 228. The sling 224 can conform to the shape of the outer shell 204, where the continuous edge 230 is positioned along edges of the front opening 212 and bottom opening 216. The sling 224 can include any suitable number of openings 228, such as two, four, ten, twenty or fifty openings, which can correspond to the number of cushion pads 10, 80, 100, 150 installed within the helmet 200. In some embodiments, the sling 224 includes an axis of symmetry S where the openings 228 on a right side of the sling 224 are mirrored on a left side thereof. However, it is understood that other configurations are possible, such as having only a portion of the sling being mirrored on the right and left sides, or such as having no symmetry between the right and left sides, for example.

[0053] In some embodiments, the continuous edge 230 may be engineered to alter the general profile of the same. For example, the continuous edge 230 may include variations in thickness, shape and/or topology, and is generally designed to enhance or generally improve the overall properties of the sling 224. It is understood that the generally continuous edge 230 may have a different material from the sling 224.

[0054] In some embodiments, the sling 224 can have a head-shaped structure, i.e., the sling 224 has a shape corresponding to a portion of a sphere (at rest, i.e., when no external forces are applied to the sling 224), as illustrated in Figures 9 to 11 .

[0055] Figures 16 and 17 show an embodiment of a sling 324 having a substantially planar structure, i.e., the sling 324 is substantially planar at rest (i.e., when no external forces are applied to the sling 324). The sling 324 is configured to hold a plurality of cushion pads 326 and includes a plurality of anchor points 328 adapted, sized and positioned to connect portions or components of the sling 324 together. As illustrated in Figure 16, the sling 324 includes regions 330 wherein the connections overlap, at the interface between two contiguous portions or components of the sling 324.

[0056] Referring back to Figures 1 to 4b, with continued reference to Figures 9 to 11 , in one embodiment, the web of material 226 is adapted to engage each cushion pad 10, 80, 100, 150 along a corresponding structure, such as the wedge 40. The resiliency of the cushion pad 10, 80, 100, 150 can enable deformation thereof for insertion within the opening 228. Once in the desired position, where the web of material 226 is provided along the wedge 40, the cushion pad is released and reverts to an initial shape and size. Each cushion pad 10, 80, 100, 150 is installed in the sling 224 in a similar manner so as to form a protective lining which can be installed within protective gear, such as the liner 202 of the helmet 200.

[0057] Now turning to Figures 15A-C, there is illustrated a sling 224 mechanically connected to an outer shell 204 of a helmet. In this embodiment, the sling 324 includes a plurality of cushion-engaging members extending inwardly of the sling 324. The cushion-engaging members are shaped and positioned such that a cushion pad 10, 80, 100, 150 can be plugged thereto. The cushion pad 10, 80, 100, 150 has a central aperture, the central aperture having a profile or being shaped such that the cushion pad 10, 80, 100, 150 can be locked to the cushionengaging members, similarly to a snap-fit assembly method (/.e., pushing the cushion pad 10, 80, 100, 150 towards the cushion-engaging members allows locking the cushion pad 10, 80, 100, 150 to the cushion-engaging members). It will have been readily understood that the cushion pad 10, 80, 100, 150 can be selectively mounted and/or unmounted to the cushion-engaging member. While the cushion-engaging members and the central aperture of the cushion pad 10, 80, 100, 150 are shown with specific dimensions and shapes, it should be noted that their respective profile may vary, as long as the profile of the cushion-engaging members have a shape or profile and characteristics being at least partially complementary with a shape or profile and characteristic of the central aperture of the cushion pad 10, 80, 100, 150.

[0058] With reference to Figures 9 to 11 , the sling 224 can include holding members 232 adapted to be connected to the outer shell 204 along the inner surface 208. In some embodiments, the holding members 232 can be fastened to the inner surface 208 of the helmet 200 using any suitable method, such as mechanical fasteners, adhesive, or interference fit, among other possibilities. The holding members 232 can be adapted to position the web of material 226 in a spaced-apart relation relative to the inner surface 208 of the outer shell 204. It is appreciated that the cushion pads 10, 80, 100, 150 can thus be positioned within the cavity 210 to form the liner 202 of the helmet 200. In this embodiment, the holding members 232 include spacers 234 extending outwardly from the web of material 226 at various locations around the sling 224, and connection pads 236 provided at a distal end of the spacers 234. The connection pads 236 are connectable to the outer shell 204, with the spacers 234 positioning the web of material 226 in a spaced-apart position relative to the outer shell 204. [0059] In this embodiment, the components of the sling 224 (e.g., the web of material 226 and/or the holding members 232) can be made of resilient material adapted to enable relative movement between the components of the sling 224, between the sling and the outer shell 204 and/or between the sling and the cushion pads. For example, the application of a force on the outer shell 204 can push the holding members 232 inwardly (e.g., towards the web of material 226) enabling compression of the cushion pads to absorb at least a portion of the energy resulting from or associated with the applied force. In some embodiments, the sling 224 is made from a plastic material or rubber.

[0060] With reference to Figs. 12a-12d, and as previously mentioned, the cushion pads 10, 80, 100, 150 may be fabricated using additive manufacturing methods. As used herein, it should be understood that the expression “additive manufacturing” refers to a manufacturing process where hardware is operated to deposit material, layer upon layer, in predetermined and/or desired geometric shapes. Additive manufacturing, or 3D printing, provides the added benefit of producing little waste and generally being more precise than traditional manufacturing methods, such as machining or casting. In accordance with one embodiment, as shown in Fig. 12a, every layer of material may be deposited in alternating orientations, such as normal to the adjacent layers. Alternatively, as shown in Fig. 12b, two layers of material may be deposited in one orientation, with a third layer deposited in an orientation normal to the adjacent two layers. Alternatively, as shown in Fig. 12c, two layers of material may be deposited in one orientation, with two layers deposited in an orientation normal to the adjacent two. Alternatively, as shown in Fig. 12d, three layers of material may be deposited in one orientation, with a fourth layer deposited in an orientation normal to the adjacent three layers. Other variations of the above may also be envisaged. Depositing layers of material during additive printing in different orientations, such as at normal angles, provides greater strength to the fabricated structure as it may be better able to resist forces being applied from different angles. It should be noted that this configuration serves an illustrative purpose only, and that other patterns may be achieved, depending on the targeted applications.

[0061] In some embodiments, the bladder 14 is mechanically independent from the internal structure 30.

[0062] In some embodiments, each layer of the cushion pads 10, 80, 100, 150, may be fabricated in a continuous process and without interruption of deposition of the material. In some embodiments, the manufacturing process allows alternately depositing layers constituting the internal structure and the bladder without interrupting the material flowing outwardly from the nozzle.

[0063] The present disclosure intends to cover and embrace all suitable changes in technology. The scope of the present disclosure is, therefore, described by the appended claims rather than by the foregoing description. The scope of the claims should not be limited by the implementations set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.

[0064] As used herein, the terms “coupled”, “coupling”, “attached”, “connected”, or variants thereof as used herein can have several different meanings depending in the context in which these terms are used. For example, the terms coupled, coupling, connected, or attached can have a mechanical connotation. For example, as used herein, the terms coupled, coupling, or attached can indicate that two elements or devices are directly connected to one another or connected to one another through one or more intermediate elements or devices via a mechanical element depending on the particular context.

[0065] In the present disclosure, an embodiment is an example or implementation of the perforation blade. The various appearances of “one embodiment,” “an embodiment” or “some embodiments” do not necessarily all refer to the same embodiments. Although various features may be described in the context of a single embodiment, the features may also be provided separately or in any suitable combination. Conversely, although the helmet and related components may be described herein in the context of separate embodiments for clarity, it may also be implemented in a single embodiment. Reference in the specification to “some embodiments”, “an embodiment”, “one embodiment”, or “other embodiments”, means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least some embodiments, but not necessarily in all embodiments.

[0066] In the above description, the same numerical references refer to similar elements. Furthermore, for the sake of simplicity and clarity, namely so as to not unduly burden the figures with several references numbers, not all figures contain references to all the components and features, and references to some components and features may be found in only one figure, and components and features of the present disclosure which are illustrated in other figures can be easily inferred therefrom.

[0067] In addition, although the optional configurations as illustrated in the accompanying drawings comprises various components and although the optional configurations of the helmet and related components as shown may consist of certain geometrical configurations as explained and illustrated herein, not all of these components and geometries are essential and thus should not be taken in their restrictive sense, i.e. should not be taken as to limit the scope of the present disclosure. It is to be understood that other suitable components and cooperations thereinbetween, as well as other suitable geometrical configurations may be used for the implementation and use of the robot cell, and corresponding parts, as briefly explained and as can be easily inferred herefrom, without departing from the scope of the disclosure and the appended claims.