Note: Descriptions are shown in the official language in which they were submitted.
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PROTECTIVE HEADGEAR
TECHNICAL FIELD
[001] The present invention is in the technical field of protective gear. More
particularly, the present invention is in the technical field of head
protection.
BACKGROUND
[002] Conventional head protection devices are in the form of a helmet ¨ non-
conforming, rigid head pieces lined with a Styrofoam or foam layer to protect
the head
from skull fractures upon direct physical contact or impact with the ground or
other
surface. Baseball and softball batters and runners also wear helmets to
protect their
heads against forces of a speeding baseball or softball, which can reach
speeds up to,
for example, as much as 90-100 mph for a pitched ball and 120 mph for the exit
speed
of a home run ball.
[003] Just like the batters, pitchers are at significant risk for concussion-
type injuries
because of their proximity to the plate. Depending on the level of
competition, pitchers
may be within 35 feet (softball) and 60 feet (baseball) of the plate after
releasing the
ball. The average and fastest exit speeds of a baseball off a swung bat has
been
measured among the top MLB players at approximately 105 mph and 120 mph,
respectively, and can hit a pitcher before the pitcher has time to react. Such
an impact
can impart a shockwave into the brain that causes it to rebound or if a helmet
is worn,
it can impart a rebound effect between the head and the helmet.
SUMMARY
[004] Embodiments of a protective device disclosed herein provide for a
protective
cap for a head of an individual. One embodiment includes a hard shell that
conforms
to the curvature of the head. The preferred cap includes a flexible,
comfortable, and
energy-distributing shell for conforming to the head of the individual so as
to define a
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surface area of protection preferably covering the frontal, temporal,
parietal, and
occipital regions of the skull. The preferred shell is of a lightweight, rigid
or semi-rigid
material with a hardness that produces load-distributing characteristics. The
shell is
preferably formed from a plurality of rigid panels that include a group of
panels that
have a geometry that conform to the curvature of the head. The plurality of
protective
panels further preferably include a group of adjacent panels to define a
flexible seam
therebetween. The adjacent panels preferably define one of a hexagonal or a
pentagonal geometry. Adjacent panels further preferably define gap
therebetween to
allow the rigid panels to flex between each other. Preferably formed in the
gap is a
flexible seam that allows the rigid panels to flex between each other. The
flexible
seam can be an air gap; or additionally or alternatively include a flexible
material
disposed within the gap. Adjacent sides of adjacent panels preferably having
the
same length extending parallel to one another over a portion of the surface
area of
protection.
[005] Another embodiment disclosed herein provides a flexible headpiece for
comfort
management that conforms to the head of the individual so as to define a
surface area
of protection over a plurality of skull regions in the head. The headpiece
preferably
has energy-absorbing and dissipating properties. Preferably disposed about or
formed
about the headpiece is a segmented protective shell made of a material that
distributes the load. The shell preferably includes rigid panels made of
material that
distributes the load. Gaps formed between the rigid panels allow the panels to
flex
between each other. The gaps can be filled with a flexible material to form a
seam
that allows the load of one panel to be transferred to the adjacent panel(s).
[006] Embodiments of the flexible headpiece are suitable for protective
applications
and preferred embodiments of the headpiece have energy-absorbing and
dissipating
properties. The preferred embodiments function to distribute the load and
absorb
energy with a comfortable fit for the user. Another preferred embodiment
includes a
flexible headpiece for conforming to the head of the individual so as to
define a surface
area of protection over a plurality of skull regions in the head. A plurality
of protective
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panels are preferably fastened to the flexible headpiece to protect the head.
Alternatively, the plurality of panels may be free to move with respect to the
headpiece
with the headpiece and the plurality of panels held in place by an outer
housing. The
plurality of protective panels preferably include a group of adjacent panels
to define a
flexible seam therebetween. Preferred panels define one of a hexagonal or a
pentagonal geometry, in which adjacent panels defining a flexible seam
therebetween
including adjacent sides of the same length extending parallel one another
over a
portion of the surface area of protection.
[007] Another embodiment of a protective cap for a head of an individual
disclosed
herein includes a flexible headpiece for conforming to the head of the
individual so as
to define a surface area of protection over a plurality of skull regions in
the head. The
preferred cap includes a plurality of protective panels fastened to the
flexible
headpiece. Each of the panels defining a center point and a central axis
extending
through the center point normal to the panel. Each panel is preferably defined
by a
plurality of interconnected sides, each side being linear in a plane
orthogonal to the
central axis and tangent to the center point so as to define a polygon in the
plane. The
plurality of panels are adjacent to one another so as to cover the surface
area of
protection, the plurality of protective panels include a group of adjacent
panels spaced
apart so as to define a seam therebetween having sides of adjacent panels
being of
equal length and parallel to one another with a flexible joint formed in each
seam.
Preferred embodiments of the protective cap includes a headpiece and shell,
which
defines a preferred profile thickness that is suited for protective
application and
minimal distraction or discomfort.
[008] The claimed invention pertains to a protective cap comprising: a
flexible
headpiece for absorbing energy of an impact load; and a segmented outer
protective
shell disposed about the flexible headpiece for distributing the impact load.
Included in
the claimed invention is a protective cap for a head of an individual
comprising: a
flexible headpiece shaped to conform to the head; and a plurality of
protective panels
fastened to the flexible headpiece and arranged adjacent to each other to
define a
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plurality of flexible seams therebetween, the flexible seams including
adjacent sides
extending parallel to one another over a portion of the surface area of
protection. Also
included in the claimed invention is a protective cap for a head of an
individual
comprising: a flexible headpiece for conforming to the head of the individual
so as to
define a surface area of protection over a plurality of skull regions in the
head; a
plurality of protective panels disposed about the flexible headpiece to
protect the head,
each of the panels defining a center point and a central axis extending
through the
center point normal to the panel, each panel being defined by a plurality of
interconnected sides, each side being linear in a plane orthogonal to the
central axis
and tangent to the center point so as to define a polygon in the plane, the
plurality of
panels being adjacent to one another so as to cover the surface area of
protection, the
plurality of protective panels include a group of adjacent panels spaced apart
so as to
define a seam therebetween having sides of adjacent panels being of equal
length and
parallel to one another; and a flexible joint formed in each seam.
BRIEF DESCRIPTION OF THE DRAWINGS
[009] Embodiments disclosed herein will be described and explained through the
use
of the accompanying drawings.
[010] FIG. 1 is a partial isometric view of one preferred embodiment of a
protective
device.
[011] FIG. 2 is a partial plan and cross-sectional view of the protective
device of FIG.
1.
[012] FIG. 3 is a cross-sectional side view of the device of FIG. 1 along line
III--III in
FIG. 2.
[013] FIGS. 4A-4D are plan, from, back and side views of another preferred
embodiment of the protective device.
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[014] FIG. 5A is a isometric view of a preferred protective panel for use in
the device
of FIG. 1.
[015] FIG. 5B is a plan view of a group of protective panels of one preferred
embodiment of the device of FIG. 1.
[016] FIG. 5C is a detailed cross-sectional view of a preferred bridge element
with
alternate embodiments of a headpiece and seam for use in the protective device
of
FIG. 1.
[017] FIG. 6 is an exploded view of another preferred embodiment of the
protective
device.
[018] The drawings have not necessarily been drawn to scale. For example, the
dimensions of some of the elements in the figures may be expanded or reduced
to
help improve the understanding of the disclosed embodiments. Similarly, some
components and/or operations may be separated into different blocks or
combined into
a single block for the purposes of discussion of some of the disclosed
embodiments.
Moreover, while the invention is amenable to various modifications and
alternative
forms, specific embodiments have been shown by way of example in the drawings
and
are described in detail below. The intention, however, is not to limit the
invention to
the particular embodiments described. On the contrary, the invention is
intended to
cover all modifications, equivalents, and alternatives falling within the
scope of the
invention as defined by the appended claims.
DETAILED DESCRIPTION
[019] Shown in FIGS. 1-3 are views of one preferred embodiment of a protective
device 10 for a head of an individual person. The device 10 preferably defines
a
surface area of protection which covers the frontal temporal regions of the
head or
skull of the individual and more preferably protects the frontal, temporal,
occipital and
parietal regions of the skull. Accordingly, the device is preferably
configured as a cap
to protect the front, top, sides and back of the head from impact injuries and
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rebound effects of high speed objects as seen for example, in sports such as
baseball
as previously described. The cap 10 can be configured as a skull cap, for
example, as
shown; or alternatively can be configured as a baseball-style cap with a
visor; or
further in the alternative, the cap can be configured with any other type of
brim to
provide a desired hat configuration. Preferred embodiments of the device 10
provide
head protection against a high-speed moving object, such as for example a
baseball
or softball moving at a speed of up to about 125 mph, for example. It should
be
understood that the device 10 can be alternatively configured to protect more
or fewer
regions of the skull.
[020] The preferred protective device 10 forms a cap having a flexible,
comfortable,
and energy-absorbing underlying headpiece 12 with a preferably segmented outer
shell 11 for conforming to the head of the individual. The headpiece 12 is
preferably
made from a deformable material that allows for flexibility to conform to
various head
sizes and/or shapes. Moreover, the headpiece 12 preferably functions to absorb
and
dissipate shock and impact energy to reduce the transfer and/or the focus of
the
energy to the wearer of the protective cap 10. The headpiece 12 is preferably
made
from an energy-absorbing material suitable for providing head and/or body
protection
in contact sports such as football or ice hockey or other sports such as for
example,
cycling, skiing or snowboarding. The energy-absorbing material is preferably
suitable
for comfort management and protection applications to provide protection from
high-
speed impact objects. An exemplary preferred material(s) for forming the
headpiece
12 are the CONFORTM foams from E-A-R Specialty Composites in Indianapolis,
Ind.
and an Aero Company. As described on the E-A-R Specialty Composites website,
the
CONFORTM foams are urethane foams that "soften and conform when exposed to
warmth, giving gentle, virtually pressure-free support. When the foams take a
direct
blow, however, their high energy-absorption characteristics enable them to
absorb up
to 97 percent of an impact. While they are slow to recover after deflection,
they
effectively resist compression set" The description can be found at
<http://www.earsc.com/HOME/products/CushioningMaterials/CONFORFoams/index.a
sp?SID=265>. The shock-absorption, energy dissipating, rate responsiveness and
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dampening properties of the preferred CONFORTM foams is described in E-A-R
Specialty Composites publication entitled, "Using Specialty Engineered Foams
in
Seating Design" (Oct. 2000). The publication is available at
<http://www.earsc.com/HOME/engineering/TechnicalWhitePapers/HumanFactors/inde
x.asp?SID=58>. However, it is to be understood that other energy absorbing or
dissipating protective materials could be used.
[021] The headpiece defines a surface area of protection preferably over the
frontal,
temporal, parietal, and occipital regions of the skull to preferably absorb
and dissipate
impact energy. Accordingly, in one preferred embodiment the device 10 the
headpiece 12 defines a preformed shaped crown for covering an upper skull
region of
the head to provide the preferred energy-absorption protection and comfort.
The
preferably preformed shape is flexible enough to conform and/or deform to a
user's
head and sufficiently elastic to return to return to its initial shape. The
headpiece 12
has an inner convex surface 12a defining the crown profile, an outer surface
12b
preferably substantially parallel to the inner surface 12a. The headpiece 12
further
defines a base 13 circumscribed about the crown profile.
[022] As is generally understood in the art, a crown profile can define the
depth or
inner volume of a cap or hat and the manner the cap sits about the head. The
higher
the profile the more space is provided between the wearer's head and the inner
surface of the cap. The lower the crown profile, the more the hat conforms to
the head
to minimize the gaps between the head and the inner surface of the cap. For
the
headpiece 12 and its preferably preformed shape, the crown profile can be any
one of
a high crown profile, a mid-crown profile or a low crown profile and more
preferably
defines a low crown profile. Because the headpiece 12 preferably conforms to
the
head of the wearer, any gap between the surface of the head of the individual
and the
device 10 is minimized and more preferably eliminated. Referring to FIGS. 1
and 3,
the cap 10 and its headpiece 12 defines various regions of protection, each of
which
preferably define a different portion of the crown profile and the overall
geometry of the
preform shape. For example, a frontal region of the headpiece 12 protecting
the
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frontal region of the skull can define a first portion of the crown profile
having a first
spherical radius of curvature R1 from a center of curvature 0. A back region
of the
headpiece protecting the parietal and occipital regions of the skull defines a
second
portion of the crown profile having a second spherical radius of curvature R2
from the
center 0 that is preferably different and more preferably greater than the
first spherical
radius of curvature R1. In one embodiment, the preformed shaped crown can
define a
half-egg or semi-ovoid shape. Alternatively, the crown profile can be
substantially
uniform over the entire headpiece such that the preformed shaped crown is
substantially hemispherical. Further in the alternative, the inner surface 12a
of the
headpiece 12 can include inner surface treatments such as, for example, one or
more
grooves 12aa and/or ridges 12ab, as seen for example in FIG. 5C. In one
preferred
aspect the grooves 12aa and/or ridges 12ab can be configured or positioned to
enhance the desired energy absorbing and dissipating characteristics of the
headpiece
12. Additionally or alternatively, the grooves 12aa and/or ridges 12ab can be
configured to provide a cooling effect to enhance comfort for the wearer.
[023] The base 13 of the headpiece 12 preferably defines a maximum
circumference
of the cap 10. In a preferred manner of wearing the cap 10, the base 13 is
located
about the wearer's head just above the brow. In one preferred aspect, the base
13
can be dimensioned to correspond to any one of a standard hat size under a
known
hat measuring system, e.g., U.S. System or U.K. system. Summarized in Table 1
below are examples of standard adult head sizes.
[024] Table 1
us
stem 6543 6/4 6/8 7 71/8 71/4 73/ 71/2 7% 7% 7% 8
Sy
UK
tem 6% 6% 6% 6% 7 7%71/4 7% 71/2 7% 7% 7%
Sys
CM 53 54 55 56 57 58 59 60 61 62 63 64
Inches 20 3/4 211/4 21 5A 22 221A 22 3/4 231/4 23
5A 24 241/2 24 3/4 251/4
[025] Again, the headpiece 12 is preferably made from a deformable material
that
allows for flexibility to conform to various head sizes and/or shapes. More
preferably,
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the headpiece 12 is preferably flexible, expandable and elastic such that the
base 13
and the crown profile can accommodate or conform to multiple standard hat
sizes for
adults or youth sizes. Alternatively, the headpiece 12 can be formed to any
desired
size to provide for a customized fit.
[026] To give the device flexibility and provide comfort when wearing, the
headpiece
material is preferably thin yet thick enough to provide the desired energy
absorbing
function in the preferred protection device 10. Referring to FIG. 2, the
headpiece 12
has a preferred thickness t ranging from 1/4 inch to about 3/8 inch. However,
thinner
or thicker materials can be used provided the headpiece provides the desired
protection and flexibility described herein. To further facilitate the
flexibility of the
headpiece 12 and conformance to the variability in human head size and shape,
the
headpiece 12 can include one or more voids, openings or holes, as seen for
example
in FIG. 6, to provide expansion to facilitate the fit. The openings can
additionally or
alternatively provide cooling, ventilation and/or enhance breathability. A
preferred
headpiece 12 can be formed or modeled from a mannequin head or other structure
to
form or construct the preferred energy-absorbing material into the desired
crown-
profile and/or base 13 configuration and dimension. A preferred mold used to
form the
headpiece 12 can be dimensioned to define the standard or customized hat sizes
previously described. Once formed, the headpiece 12 can be perforated, cut or
punctured to provide any desired holes or openings.
[027] Fastened to the headpiece 12 are a plurality of protective panels 14
(14i, 14ii,
...14ith) which collectively form the energy distributing preferably segmented
outer
shell 11. There are a number of different ways that the headpiece 12 and the
panels
14 can interface. For example, the load distributing panels 14 can be
mechanically
attached to the headpiece 12 by a fastener or alternatively, the headpiece 12
can
include a group of pockets (not shown) in which each panel 14 is housed in a
pocket.
Alternatively, the panels 14 can be chemically fastened to the headpiece 12
for
example by an appropriate adhesive. Further in the alternative, the panels 14
can be
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layered together on the inside surface of an outer jacket, housing or outer
cap which
together is placed over and/or coupled to the headpiece 12.
[028] The protective hard outer shell 11 defined by the panels 14 protects the
head
by spreading out and distributing the load of a high-speed impact object to
the head.
The protective panels 14 are preferably made of lightweight, rigid or semi-
rigid
material. Moreover in preferred embodiments, each panel defines a durometer
scale
hardness and/or an impact resistance that is typical of head protective gear
such as
helmets including for example batting or football helmets.
[029] The panels are preferably aligned and spaced over the headpiece 12 and
the
defined surface area of protection to form a flexible joint or seam 16
therebetween
which interconnects or spatially relates the panels 14 to form the load-
distributing shell
11. Additionally, the segmentation and or space between panels 14 are
preferably
configured to allow for flexibility between the panels which can provide or
enhance the
overall flexibility and comfort of the protective cap 10. Accordingly, the
plurality of
protective panels 14 preferably include a group of adjacent panels 14 which
define the
seam(s) 16 therebetween. The seams 16 provide the device 10 with the
flexibility by
permitting the panels 14 to move with respect to one another in conformance to
the
wearers head. To maximize the protection of the device 10 while facilitating
flexibility,
the seams or spacing between the adjacent panels is preferably minimized. In
preferred embodiments, the spacing between adjacent panels define a seam width
w,
as shown for example in FIG. 5B, which has a width that allows flexibility
between the
panels and allows load from one panel to be transferred to adjacent panels. In
one
preferred embodiment, seam width w ranges from 1 mm - 3 mm. Moreover, the
width
w of the seams 16 preferably vary with the expansion or flex of the protective
device
10. In a preferred embodiment, the gap or seam width w can displace or expand
up to
3 mm and more preferably can expand up to 1 mm. The expansion of the seam 16
can be further limited to expand to an amount less than 1 mm, such as for
example,
from 0.5 mm. to 1 mm. and more preferably any one of 0.9 mm, 0.7 mm or 0.6 mm.
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[030] The seams 16 can provide for an air gap between the panels or
alternatively,
the seams 16 can include disposed therein a flexible, load bearing and/or
distributing
energy absorbing material 16', such as for example polyurethane or silicone,
to
interconnect the panels 14, as seen for example in FIG. 5C. The seams 16
preferably
distribute impact loads to adjacent panels and more preferably distribute
impact loads
over all the panels. Accordingly, in a preferred embodiment of the device 10,
the
seams 16 formed by the spaced apart panels 14 are preferably interconnected
with
one another. Additionally or alternatively, the device 10 can include a bridge
element
or segment that crosses over the seam 16. The protective cap of claim 33,
wherein
the plurality of panels are spaced apart to define a seam, the cap further
comprising a
bridge segment connecting two panels and extending over the seam. For example,
shown in the cross-sectional view of FIG. 5C are two adjacent panels 14x, 14y
with the
seam 16 in between. One panel 14x can include a cantilevered element or
segment
14'xx that bridges the seam 16 and overlaps the adjacent edge of adjacent
panel 14y.
The bridge element 16 can extend lengthwise over the axial length of the seam
16 or
be shorter than the seam length. The bridge element 14'xx can provide for
additional
protection and/or facilitate sliding engagement between adjacent panels 14.
Moreover, preferred embodiments of the panel geometry and flexibility
described
herein provide the protective device 10 and its shell 11 with an outer surface
that is
preferably without sharp curves, edges, sharp points or breaks.
[031] In the preferred embodiment of the protective device 10 shown in FIGS. 1-
3, the
adjacent panels 14 have sides that preferably define one of a hexagonal or a
pentagonal geometry. Adjacent panels 14 are preferably dimensioned, spaced and
aligned with one another so that sides of the adjacent panels having the same
length
are adjacent to one another to define the interconnected seams 16 previously
described. Moreover, in the particular embodiment of the device 10, the panels
14 are
preferably aligned and interconnected with one another such that the
protective device
or cap 10 will define a truncated icosohedron so as to more generally mimic a
surface
of a soccer ball.
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[032] Shown in FIGS. 4A-4D are various views of a preferred embodiment of the
protective cap 10 having a preferred pattern of whole and partial hexagonal
and
pentagonal panels 14. The preferred pattern arranges the panels 14 and seams
16 in
a manner to facilitate the desired flexibility and protection as described
herein. The
cap 10 defines a frontal region 10a, a back region 10b and a vertical plane P
extending from the back region 10b to the frontal region 10a. The cap 10 and
the
pattern of its panels 14 are preferably symmetrical about the vertical plane
P.
Referring to the front and back views of FIGS. 4B and 4C, the preferred
pattern
includes a first preferred group of panels having a first whole hexagonal
panel 14a
centered in the frontal region 10a so as to be bisected by the vertical plane
P and a
second whole hexagonal panel 14b centered in the back region region 10b so as
to be
bisected by the vertical plane P. Now referring to the plan view of the top of
the
protective cap 10 in FIG. 4A, the first preferred group of panels 14 includes
a third
whole hexagonal panel 14c and a fourth whole hexagonal panel 14d adjacent to
the
third hexagonal panel to define a central seam 16a preferably axially aligned
along the
vertical plane P. The third and fourth hexagonal panels 14c, 14d are
preferably
located between the first and second hexagonal panels 14a, 14b. A first whole
pentagonal panel 14e is preferably disposed between the first, third, and
fourth whole
hexagonal panels 14a, 14c, 14d and bisected by the plane P. A second whole
pentagonal panel 14f is preferably disposed between the second, third and
fourth
whole hexagonal panels 14b, 14c, 14d and bisected by the plane P.
[033] Referring to the side view of the protective cap 10 shown in FIG. 4D,
the
preferred pattern includes a second group of panels 14 laterally of the plane
P that
includes partial panels, and more preferably, includes half-hexagonal and half-
pentagonal panels that are disposed along the base 13 with their edges aligned
along
the base 13. More specifically, the preferred second group of panels includes
a first
half-pentagonal panel 14g adjacent the second whole hexagonal panel 14b and a
second half-pentagonal panel 14h adjacent the first whole hexagonal panel 14a.
The
preferred first and second whole hexagonal panels preferably have their edges
aligned
along the base 13. Preferably disposed between the first and second half-
pentagonal
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panels 14g, 14h are a first half-hexagonal panel 14i and a second half-
hexagonal
panel 14j adjacent the first-half hexagonal panel 14i. On each side of the
plane P
preferably formed between each of the adjacent and spaced apart panels along
the
base 13 are five gaps or seams 16b, 16c, 16d, 16e, 16f to preferably provide a
total of
ten (10) expandable seams 16 spaced along the base 13 of the cap 10. As
previously
noted the circumference of the cap 10 defined by the base 13 can define one
and
preferably more than one hat size. In one preferred aspect, the expandability
of the
ten gaps or seams 16b, 16c, 16d, 16e, 16f formed along the base 13 between the
panels 14 can define the expandability of the base and the cap 10 overall and
the
ability to cover multiple hat sizes. For example, under the U.S. Department of
Defense
Military Handbook DOD-HDBK-743A: "Anthropometry of U.S. Military Personnel
(Metric)" (Feb. 13, 1991) at Table 86b, percentiles values for head
circumference is
provided. In the first row of Table 2 below are the percentile values for the
head
circumferences in cm of "US Army Men (1988)" taken from Table 86b and shown in
the second row of the table. The "Head Circumference" is the maximum
horizontal
circumference of the head, measured with the tape passing above the brow-
ridges and
the ears.
[034] Table 2
Percentile 1st 2nd 5th 10th 25th 50th 75th 90th 95th 98th 99th
Head
Circumference
(cm) 53.3 53.7 54.3 54.8 55.7 56.8 57.8 58.7 59.4 60.1 60.7
Difference over
percentiles (cm) 1 0.9 1 0.7 0.6
Gap per
segment over
segments
(mm) 1 0.9 1 0.7 0.6
[035] In row three, below the head circumference values, are the "Difference
over
percentile (cm)," which shows five difference values for each of five grouped
percentiles. For example, the third difference value between the fiftieth
(50th) and
seventy-fifth (75th) percentile is 1 cm., which corresponds to the difference
between
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head circumference values (56.8 and 57.8 respectively) of the two percentile
values.
In the last row of the Table 2, a "gap per segment" in millimeters identifies
for each of
the ten gaps or seams 16b, 16c, 16d, 16e, 16f an amount of displacement or
expansion for the cap 10 to cover or fit multiple percentiles or head
circumferences.
Under Table 2, five configurations of hat size and seam expansion are
identified for
covering the 1st through the 99th percentile values of the given head
circumference.
Thus for example, a preferred cap 10 with a base fitting a head circumference
of 53.3
cm. with each of the preferred ten seams 16b, 16c, 16d, 16e, 16f expanding up
to 1
mm can fit or cover each of the 1st, 2nd and 5th percentiles.
[036] Referring again to FIG. 4D, the preferred pattern of panels 14 of the
cap 10
include a third group of panels located laterally of the plane P between the
first and
second group of panels previously described. The third group of panels
preferably
include a third whole pentagonal panel 14k between one of the third and fourth
whole
hexagonal panels 14c, 14d and the first and second half-hexagonal panels 141,
14j.
The preferred third group of panels of the preferred panel pattern includes a
fifth whole
hexagonal panel 141 and a sixth whole hexagonal panel 14m disposed about the
third
whole panel 14k and between the first and second groups of panels previously
described. For the preferred embodiment of the cap 10 shown in FIGS. 4A-4D,
the
cap 10 can be assembled with a total of twenty (20) panels.
[037] Shown in FIG. 5A is an exemplary embodiment of a protective panel 14.
The
panel preferably defines a center point C and a central axis A--A extending
through the
center point C normal to the panel 14. Each panel 14 is preferably defined by
a
plurality of interconnected edges or sides 18 (18a, 18b, 18c, . . . 18nth
sides). Each
side 18 preferably defines a linear projection 18' in a plane P orthogonal to
the central
axis A--A and more preferably tangent to the center point C so as to define a
polygon
PG in the plane, such as for example the hexagon shown in FIG. 5A or
alternatively a
pentagon. The panels 14 can include one or more voids, holes or openings 17,
as
shown in FIG. 5A or the preferred cap of FIGS. 4A-4D, to provide facilitate or
enhance
cooling and or breathability.
14
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[038] As formed about the protective device 10, each of the plurality of
panels 14
preferably has an outer convex surface 15a and an opposite inner preferably
concave
surface 15b defining the thickness of the panel 14 in between. Preferably, the
panels
14 have a thickness from 1/10 in. to 1/8 in. The thickness can be constant
over the
panel or alternatively variable. The outer convex surface of the protective
panels 14
preferably prevents or eliminates flat surfaces in the device 10 that can
cause sharp
edges or corners. In preferred embodiments of the panel 14, the outer convex
surface
15a can define a panel width that spans across the surface 15a and passing
through
the center C to define a panel width that preferably facilitates load
distribution and
conformance to the head. The inner concave surface 15b defines one or more
radii of
curvature to substantially conform the protective panels 14 to the head of an
individual.
Referring to FIGS. 3 and 1, the panels 14 collectively preferably define a
preferably
variable spherical radius of curvature RS so that the device 10 conforms to a
range of
head profiles. More specifically, the collective interconnection of panels 14
define an
internal profile of the shell 11 with a spherical radius of curvature R that
varies in a
manner to conform to the head of an end-user of the device 10. More
preferably, each
panel 14 conforms to the portion of the headpiece to which it adheres.
Accordingly,
the inner surface 15b of each panel extends or spans preferably parallel over
the
outers surface of the headpiece 12. In a preferred embodiment, the headpiece
defines
at least one spherical radius of curvature R1, R2 from a common center point
0, and
each panel 14 of the outer segmented shell 11 defines at least one spherical
radius of
curvature RS from the common center point 0. The spherical radius RS of the
shell at
the particular panel 14 outside of the headpiece 12 defining the spherical
radius R1,
R2 is greater than the spherical radius of curvature of the headpiece 12 by a
preferred
amount ranging between 1/4 to about 3/8 inch. In one preferred embodiment in
the
formation of the panels 14, the profile of mold or head used to form the
headpiece 12
can be modeled in a computer and characterized by a sufficient number of
spherical
radii of curvatures. From the computer model, a corresponding shell can be
determined by incorporating an offset, such as for example and increase in the
spherical radii by a common factor, such as for example, 1/4 inch to 0.35
inch. The
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modeled shell can be segmented into the desired panel geometries. Each panel
14
can be printed out for example, on a 3D computer from the computer model and
appropriately mapped onto and fastened to the headpiece 12 to provide the
assembled protective device 10. The individual panels 14 can be fabricated by
alternate technique provided the panels provide for the protection,
flexibility and
comfort in wear as described.
[039] Preferably, as shown in FIG. 5B, adjacent protective panels provide for
adjacent
parallel sides of 18aa, 18ba of equal length Ito define the seams 16 of the
shell 11.
More preferably in plan, preferred embodiments of the device 10 provide for a
group of
adjacent panels which define a plurality of equilateral polygons in plan such
as for
example as the hexagons and pentagons as shown. In the alternative, the
protective
panel 14 can define other polygons in plan. Accordingly, the panel 14 can be
formed
with any number of sides, for example, ten or fewer sides, eight or fewer
sides, or six
or fewer sides. Shown are adjacent panels 14 a', 14b', 14c' of varying
geometry.
Further in the alternative, the group of adjacent protective panels can be
defined by
panels of similar geometry. Even further in the alternative, groups of panels
can be
integrally formed as an integral or singular panel defining its own larger
geometry. For
example, referring to the first, second, and third groups of panels previously
described
with respect to FIGS. 4A-4D, any one of the groups of panels 14 can be formed
integrally. By forming larger sized panels 14, the number of seams 16 may be
reduced, provided the resulting geometries and device 10 can still adequately
and
comfortably protect the wearer's head in a manner as described herein.
[040] As previously noted, the protective device 10 preferably wears like a
cap on an
individual. The cap 10 can be configured as a baseball-style cap with a visor
or brim.
A preferred embodiment of the cap 100 is shown in an exploded view in FIG. 6.
Shown is the headpiece 12, the outer preferably segmented shell 11 and an
outer cap
or housing 20, shown as a baseball cap. The outer cap 20 can be a standard
size
baseball cap preferably large enough to house the device 10. Accordingly,
where the
headpiece 12 and device 10 define a standard hat size, the outer cap 20 is
preferably
16
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1/2 to one standard size larger. Alternatively or additionally, the outer cap
20 can
include a lip or seal 22 that can be folded over the base 13 of the headpiece
12 to
secure the protective device 10 within the housing 20. Further in the
alternative, the
outer cap 20 can include or the lip or seal 22 can form and internal shelf
along the
edge of the outer cap 20 to hold the protective device 10 in place. Moreover
in
another alternate aspect, with an outer cap 20 to hold the headpiece 12 and
shell 11
together, the headpiece 12 and shell 11 can be permitted to move independently
with
respect to one another so as not to require for any fixture between the
headpiece 12
and shell 11.
[041] The features described herein of the protective device 10 can be
customized
appropriately to provide the desired protection for a given application. For
example,
the number of panels 14, the geometry of the panels 14 and their location on
the
headpiece 12 can be varied to provide the desired protection over
particularized
regions of the skull or head. In one preferred aspect, the number and size of
protective panels 14 are related to the size of the cap 10 for example as
measured in
hat size. In addition to the general shape or geometry of the panels 14, the
thickness
and rigidity of the panels can be varied individually to suit a particular
application.
Moreover as described, the headpiece 12 can define a customized profile,
configuration and thickness that minimizes distractions and discomfort to the
wearer.
[042] The above Detailed Description of embodiments of the disclosure is not
intended to be exhaustive or to limit the invention to the precise form
disclosed above.
While specific examples for the invention are described above for illustrative
purposes,
various equivalent modifications are possible within the scope of the
invention, as
those skilled in the relevant art will recognize. In conclusion, the present
invention
provides novel systems, methods and arrangements for protective headgear.
While
detailed descriptions of one or more embodiments of the invention have been
given
above, various alternatives, modifications, and equivalents will be apparent
to those
skilled in the art without varying from the spirit of the invention. For
example, while the
embodiments described above refer to particular features, the scope of this
invention
17
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also includes embodiments having different combinations of features and
embodiments that do not include all of the described features.
18
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