Note: Descriptions are shown in the official language in which they were submitted.
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DEVICE FOR ABSORBING AND RETAINING SWEAT
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. Patent Application Serial No.
15/157,385, filed
on May 17, 2016, titled DEVICE FOR ABSORBING AND RETAINING SWEAT, which is a
continuation-in-part of U.S. Patent Application Serial No. 14/535,247, filed
on November 6,
2014, titled DISPOSABLE ABSORBENT INSERT FOR AN ATHLETIC READ COVERING,
which is a continuation-in-part of U.S. Patent Application Serial No.
13/709,913, filed on
December 10, 2012, titled DISPOSABLE ABSORBENT INSERT FOR AN ATHLETIC READ
COVERING, which is a continuation of U.S. Patent Application Serial No.
12/416,529, filed on
April 1, 2009, titled DISPOSABLE ABSORBENT INSERT FOR AN ATHLETIC HEAD
COVERING, which claims the benefit of U.S. Provisional Application No.
61/041,388, filed on
April 1, 2008, titled DISPOSABLE ABSORBENT INSERT FOR AN ATHLETIC READ
COVERING.
FIELD OF THE DISCLOSURE
The disclosed invention relates to a device for absorbing and retaining sweat.
More
specifically, it relates to a wearable, disposable device that a user can put
into contact with the
user's head to prevent sweat from dripping onto the user's face. In one
embodiment, the device
contains an adhesive layer and is inserted into headwear. In one embodiment,
the device is a
disposable band that secures around a user's head.
BACKGROUND OF THE INVENTION
Sports have been a form of hobby, community involvement, and source of
exercise
for people for decades. The athletic equipment industry is stable and is
one that is
becoming more and more technologically advanced. Athletes are constantly
looking for new
ways to enhance their performance and gain a competitive edge over their
opponents.
Workers, such as construction workers, make up a large portion of the
workforce and
work outside during most, if not all, times of the year, regardless of the
season. Construction
workers frequently have to wear safety helmets or hard hats while they are on
site to protect
themselves from contact injuries.
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A common problem that many athletes and construction workers experience is
sweat
dripping from their foreheads into their eyes. Inhibiting sweat or any type of
moisture from
dripping down into the eyes, nose, mouth and other areas of the face will
allow the
individual to concentrate on the task at hand and not be distracted or
uncomfortable during
his or her performance. The use of an insert enhances the performance and
comfort of an
individual during activity by mitigating the possibility of sweat and oil
dripping down onto
the individual's face during activity and impairing his or her vision.
Currently, there are a variety of moisture absorbing devices for absorbing
sweat and
other moisture away from the head of an individual during various activities.
Such absorbent
devices have been used as an insert in a cap, hat, hardhat or sun visor.
However, a problem
with many inserts is that they are difficult to clean and are not easily
replaced when soiled or
saturated.
Moreover, many disposable inserts are not well shaped for the contours of
headwear.
SUMMARY OF THE INVENTION
In one aspect, a disposable absorbent insert for fitting against a forehead-
contacting,
curved inside surface of a user's head covering comprises a moisture wicking
layer; a liquid
absorbent core layer; a liquid impervious layer; an adhesive layer comprising
a repositionable
pressure-sensitive adhesive; and a release liner layer. A top edge of the
insert comprises a
plurality of slits to facilitate fitting of the insert onto the curved inside
surface of the head
covering.
In another aspect, a method of using a disposable absorbent insert on a
forehead-
contacting, curved inside surface of a user's head covering is described. The
insert comprises a
liquid absorbent layer, an adhesive layer, and a release liner layer, wherein
a top edge of
the insert comprises a plurality of slits. The method comprises separating the
release liner
layer from the adhesive layer and contacting the adhesive layer to the curved
inside surface
of the head covering while manipulating the top edge of the insert via the
slits to fit the
insert onto the curved inside surface of the head covering without overlapping
areas of the
insert.
In one aspect, a disposable, flexible, absorbent band for securing around a
user's head
comprises at least one moisture wicking layer and a liquid absorbent core
layer. The band may
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have two open ends that tie together or may made at least partially of an
elastic material to
enable the user to stretch the band around the user's head.
This summary is provided to introduce concepts in simplified form that are
further
described below in the detailed description. This summary is not intended to
identify key
features or essential features of the disclosed or claimed subject matter, and
is not intended
to describe each disclosed embodiment or every implementation of the disclosed
or claimed
subject matter, and is not intended to be used as an aid in determining the
scope of the
claimed subject matter. Many other novel advantages, features, and
relationships will
become apparent as this description proceeds. The figures and the description
that follow
more particularly exemplify illustrative embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top-down view of one embodiment of the disclosed insert.
FIG. 2 is a top-down view of the disclosed insert of FIG. 1.
FIG. 3 is a top-down view of one embodiment of the disclosed insert
illustrating
variations in size and shape of the liner.
FIG. 4 is a top-down view of one embodiment of the disclosed insert
illustrating
variations in size and shape of the liner.
FIG. 5 is a side view of an athletic helmet with the insert of FIG. 1
positioned inside
the front portion of the helmet.
FIG. 6 is a side view of a hat with the insert of FIG. 1 positioned inside the
front portion
of the hat.
FIG. 7 is a side view of a helmet with the insert of FIG. 1 positioned inside
the front
portion of the helmet.
FIG. 8 is a perspective view of an athletic helmet with the insert of FIG. 1
positioned
.. inside the front portion of the helmet.
FIG. 9 is a bottom view of an athletic helmet with the insert of FIG. 1
positioned inside
the front portion of the athletic helmet.
FIG. 10 is a bottom view of a hat with the insert of FIG. 1 positioned inside
the front
portion of the hat.
FIG. 11 illustrates application of the insert of FIG. 1 into the front portion
of an athletic
helmet.
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FIG. 12 illustrates application of the insert of FIG. 1 into the front portion
of a hat.
FIG. 13 is a partial sectional view of the disclosed insert.
FIG. 14 is an exploded view of one embodiment of the disclosed insert.
FIG. 15 is an exploded view of one embodiment of the disclosed insert.
FIG. 16 is an exploded view of one embodiment of the disclosed insert.
FIG. 17 is a perspective view of one embodiment of the disclosed insert
positioned on the
suspension headband of the construction hard hat.
FIG. 18 is a top-down view of one embodiment of the disclosed insert.
FIG. 19 is a top-down view of one embodiment of the disclosed insert.
FIG. 20 is a top-down view of one embodiment of the disclosed insert.
FIG. 21 is a top-down view of one embodiment of the disclosed insert.
FIG. 22 is a top-down view of one embodiment of the disclosed insert.
FIG. 23 is a top-down view of one embodiment of the disclosed insert.
FIG. 24 is a top-down view of one embodiment of the disclosed insert.
FIG. 25 is a top-down view of one embodiment of the disclosed insert.
FIG. 26 is a top-down view of one embodiment of the disclosed insert.
FIG. 27 is a top-down view of one embodiment of the disclosed insert.
FIG. 28 is a top-down view of one embodiment of the disclosed insert.
FIG. 29 is a top-down view of one embodiment of the disclosed insert.
FIG. 30 is a top-down view of one embodiment of the disclosed insert.
FIG. 31 is a top-down view of one embodiment of the disclosed insert.
FIG. 32 is a perspective view of one embodiment of the disclosed insert.
FIG. 33 is a perspective view of one embodiment of the disclosed insert.
FIG. 34 is a back perspective view of one embodiment of the disclosed insert.
FIG. 35 is a top-down view of one embodiment of the disclosed insert.
FIG. 36 is a front view of one embodiment of the disclosed insert.
FIG. 37 is a right side perspective view of one embodiment of the disclosed
insert.
FIG. 38 is a right side view of one embodiment of the disclosed insert.
FIG. 39 is a partial sectional view of the disclosed insert.
FIG. 40 is a partial sectional view of the disclosed insert.
FIG. 41 is a partial sectional view of the disclosed insert.
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FIG. 42 is a partial section view of the disclosed insert.
DETAILED DESCRIPTION
Various user interfaces and embodiments will be described in detail with
reference to the
drawings, wherein like reference numerals represent like parts and assemblies
throughout the
several views. Reference to various embodiments does not limit the scope of
the claims attached
hereto. Additionally, any examples set forth in this specification are not
intended to be limiting
and merely set forth some of the many possible embodiments for the appended
claims. It is
understood that various omissions and substitutions of equivalents are
contemplated as
circumstances may suggest or render expedient, but these are intended to cover
application or
embodiments without departing from the spirit or scope of the claims attached
hereto. Also, it is
to be understood that the phraseology and terminology used herein are for the
purpose of
description and should not be regarded as limiting.
One embodiment of this disclosure relates to a disposable insert that wicks
moisture
away from the user's forehead or other facial surface. The insert can be a
disposable,
moisture-absorbing device that is affixed to headwear, such as a helmet, hat,
hard hat, goggles,
or facemasks. Specifically, the insert can be affixed to athletic head
coverings used in sports,
such as, but not limited to, golf, motocross, cycling, baseball, football,
hockey, and lacrosse.
For example, the insert can attach to the portion of the headwear that is
normally in contact with
the wearer's forehead and/or temples. In another example, the insert can
attach to a chinstrap of
athletic headwear. Alternatively, the insert can attach itself to a user's
head using other means
that do not require a head covering. The disposable, absorbent insert is
specifically designed
to fit within the aforementioned headwear and other related head coverings.
In one embodiment, the material from which the disposable insert is comprised
is not
elastic. In another embodiment, at least some of the material from which the
disposable insert is
comprised is elastic. For example, the absorbent portion of the insert can be
made from a non-
elastic material, whereas the fabric or foam that covers the absorbent part
can be made from
elastic material. In another example, both the absorbent portions and the
fabric or foam cover can
be made from, or include, elastic material. In some embodiments, the insert is
made using
materials similarly used in the making of feminine hygiene pads. The insert
can, in some
embodiments, be recyclable or made of biodegradable materials. Additionally,
the materials used
in the insert can be breathable so the insert does not block ventilation from
the head covering. In
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some embodiments, any of the layers can incorporate flame-resistant fibers, as
described further
below.
The disposable absorbent insert can be adhered to the curved inside surface of
the
headwear. The insert can be easily attached to the headwear immediately before
activity and
can then be removed from the headwear and discarded after physical activity
has ceased. In
addition, a soiled insert may be replaced with a fresh insert during
activities (e.g., during a
break, during a timeout, between periods, at halftime, etc.).
One embodiment of a device for absorbing and retaining sweat is an insert, as
illustrated
in FIGS. 1-31. FIGS. 1-14 illustrates various embodiments of an insert 10,
wherein the insert 10
is intended to attach directly to the inside surface of headwear 20. FIGS. 1-4
are a view of one
embodiment of an insert 10, wherein the insert 10 is laying flat. FIGS. 5-7
are side views of
various types of headwear 20 (for example, a hockey helmet, hat, hard hat,
welding helmet, and
motor sport or racing helmet), illustrating the orientation of the insert 10
within the headwear
20, from the side. FIG. 8 is a perspective view of the headwear 20
illustrating the orientation of
the insert 10 within the headwear 20, when the insert attaches directly to the
headwear 20. FIGS.
9 and 10 are bottom views of the headwear 20 illustrating the orientation of
the insert 10 within
the headwear 20. FIGS. 11 and 12 illustrate one example of how a user can
attached the insert 10
into headwear 20.
FIG. 13 is a partial sectional view of an insert 10 illustrating the layers of
the insert 10.
FIGS. 14-16 are exploded views of the layers of the insert 10 according to
different
embodiments. For example, FIG. 14 illustrates an embodiment that can be
attached directly to
the inside of headwear 20. FIGS. 15 and 16 illustrate embodiments that can be
attached to, for
example, the forehead-contacting surface of a headband portion of a headwear
suspension
system, such as a construction hard hat, welding helmet, bump cap, visor, or
protective headwear
(hereinafter referred to as a "suspension headband").
FIGS. 15-31 illustrate various embodiments of an insert 10, wherein the insert
10 is
intended to attach to a suspension headband, such as a construction hard hat
suspension
headband. Generally, the insert 10, when intended to attach to a suspension
headband, has a
rectangular main body and can have at least one tab to wrap around the edge of
the suspension
headband and secure the insert 10 in place. FIG. 17 is a perspective view of
the headwear 20
illustrating the orientation of the insert 10 within the headwear 20, when the
insert 10 attaches to
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the suspension headband of a construction hard hat. FIGS. 18-31 illustrate
various attachment
configurations for the insert 10.
This device for absorbing and retaining sweat can, in one embodiment, be
fitted against
the inside surface of an athletic helmet or hat or a construction hard hat.
The insert, when
placed on the front portion of the helmet, hat, or hard hat, functions to wick
moisture away
from the head of the user and prevent moisture from dripping down into the
eyes, nose, mouth
and overall facial area of the user. If placed at the back of a helmet, hat,
or hard hat, it can also
prevent moisture from dripping down onto the neck of a user. The insert 10 can
be in direct
contact with the user's forehead and can be formed of an absorbent material.
In one
embodiment, as illustrated in FIGS. 14-16, the insert 10 is comprised of
several layers. These
layers function to wick moisture away from the user's forehead, trap moisture
inside the
disposable insert, and prevent moisture from dripping down onto the face of
the user. In
another embodiment, the device for absorbing and retaining sweat can be a band
50, such as a
headband or sweatband, that secures around a user's head. In this embodiment,
the band 50 is
comprised of several layers, as illustrated in FIGS. 39-41.
The device for absorbing and retaining sweat can benefit its user in many
ways. The
most apparent benefit is keeping sweat originating on the user's forehead and
hair from
dripping down onto the user's face or neck. When perspiration drips down onto
a user's face,
it can impair the user's vision. This impairment of vision, in the case of
athletes, can be a
painful annoyance and can disrupt the play and overall performance of the
athlete during the
run of play. In the case of construction workers or racecar drivers, impaired
vision can result in
distractions and severe injury.
In some activities (for example, hockey, motocross, cycling, golf,
construction, or
military tactical activities), many individuals use glass/plastic facial
shields, goggles, glasses,
or other eyewear, which have a high tendency to fog up during use due to
perspiration and
moisture entering into the area between the user's face and the glass or
plastic barrier. The
disposable insert of this disclosure can help its user by absorbing the sweat
and eliminating
almost all perspiration from dripping down onto the user's face or face
covering. This will
greatly decrease the probability of the glass/plastic barrier fogging up and
will not impair the
user's vision during the activity. This enables hockey players, for example,
to compete at a high
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level without the distraction of a fogged facial shield. For construction
workers or military men
and women, this reduces a safety risk associated with a fogged facial shield.
Additionally, headwear, such as a helmet or hard hat, is usually unable to be
thoroughly
washed and, therefore, will lock moisture, oils, and odors in. Use of the
insert enables the sweat,
oils, and odors to get locked in the insert and, therefore, reduces scents
odors from accumulating
in the head covering.
Skin hygiene is another important benefit from using the insert 10 or band 50.
Many
adult and teenage athletes who wear helmets or sweatbands during their
sporting activities
experience increased skin irritation and facial acne during participation
while in season.
Construction workers may be subject to skin irritation throughout every
season, especially the
hot, summer months. Sweat and oil from the user's hair and forehead can drip
down onto
the face, which can clog facial pores and cause unwanted facial blemishes.
Also, the pressure
and direct contact that a user's forehead has with the helmet or hard hat can
cause skin
rashes and increased acne as well. The disposable device can prevent sweat and
oil from
dripping down onto the face and clogging the user's facial pores. The soft
material of which
the disposable device is made can provide a clean and comfortable barrier
between the user's
forehead and helmet or hard hat, when using the insert 10, and can eliminate
skin irritation
and blemishes caused by the friction between the forehead and the inside
surface of the
helmet or hard hat. In some embodiments, the insert 10 or band 50 may have an
FDA-approved
skin-contacting material and/or may contain acne cream, other acne topicals,
or an antibacterial
or antimicrobial. The insert 10 or band 50 could also contain lotion, aloe,
vitamins,
pharmaceuticals, or bug spray and can be hypoallergenic, latex free, or both.
Further, as
described elsewhere in the disclosure, the insert 10 or band 50 may be flame
resistant.
In one embodiment, illustrated in FIG. 1, a length Li of the insert 10 is
between 8 and 9
inches (ex: 8.8379 inches) and a width W1 of the insert is between 3 and 4
inches (ex: 3.25
inches). In another embodiment, the disposable insert can have the dimensions
of: Length L:
180 mm to 330 mm (e.g., length = 250 mm); Width W: about 100 mm (e.g., width =
97 mm);
Thickness T: about 2 mm to about 10 mm (or even thinner, from about 2-7 mm
(e.g.,
thickness = 4-5 mm)). FIGS. 3 and 4 illustrate variations in size and shape
that the liner 10 may
have. FIG. 3 illustrates the outer border variations and FIG. 4 illustrates
variations in the inner
and outer portions of the liner according to two different sizes, wherein a
preferred embodiment
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is slightly wider and has a smaller angle along a lower curved edge 22. For
example, the corner
radius of the lower portion of rounded end edges 26, 28 can be 0.50 inches but
is preferably 0.51
inches.
In one embodiment, illustrated in FIG. 31, the insert 10 is used in the
suspension
headband of headwear 20, such as a helmet or hard hat, and has length L3,
width of the main
body W3, width of the main body and tabs W4, and tab gap width Gl. Length L3
can be between
and 11 inches (for example, 10.375 inches). Width W3 can be approximately two
inches and
width W4 can be approximately three inches. Gap width G1 can be between one
and two inches
(for example, 1.60 inches) and the width of each tab can be between 0.5 and
1.0 inches (for
10 example, 0.80 inches).
In one embodiment, as illustrated in FIG. 2, each insert 10 is generally
uniform in
thickness and has a lower curved edge 22 and rounded end edges 24 and 26. In
some
embodiments, the main body of the insert 10 is uniform in thickness while the
edges of the insert
10 form a seal that has a thinner thickness than the main body. Each insert 10
has a top edge
28, which is interrupted by one or more slits 30, thereby creating gaps or
grooves 30a, 30b,
which are cut through all layers of the insert and angled towards a central
portion of the insert.
In one embodiment, two gaps 30a, 30b are provided, and they are angled
inwardly toward a
central portion 31 of insert 10. For example, the gaps 30a, 30b may extend
from 40-50 degree
angles from the top edge 28 toward a central portion 31, and the gaps 30a, 30b
may be broader
near top edge 28 than the central portion 31. In another example, the corner
radius of the gaps
30a, 30b near the central portion 31 is 0.13 inches.
The gaps 30a, 30b allow insert 10 to naturally follow the contours of the
inside
curved surface of headwear 20. Moreover, such angling of the gaps 30a, 30b
allows the gaps
to lie naturally along headwear 20 contour lines, such as front-to-back lines
shown in FIGS.
5-7. Accordingly, the gaps 30a, 30b caused by slits 30 are least obtrusive to
the user. The
top edge 28 is thus divided into outer top edge portions 28a, and 28c and
inner top edge
portion 28b. Top edge portions 28a and 28c are generally curved, while top
edge portion 28b
is generally linear. However, in some embodiments, top edge portions 28a, 28b,
and 28c can be
generally linear or collinear. The corners of the inner top edge portion 28b
that contact the gaps
30a, 30b can each have a corner radius of 0.27 inches.
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In one embodiment, as illustrated in FIGS. 18, 24, and 25, each insert 10 is
configured to
attach to the inside of a hat, helmet, or a hard hat suspension headband, is
generally uniform in
thickness, has a rectangular main body, and at least one tab. However, as
illustrated in FIG. 30,
some embodiments of the insert 10 that are configured for attachment to the
inside of a helmet or
hard hat suspension headband do not have a tab. The tab can be an adhesive tab
34, a hook and
loop tab 36, or a snap/button tab 38.
The tab(s) 34, 36, 38 may have any variety of configuration, but preferably
protrude from
the top or bottom edge of the rectangular main body of the insert. For
example, the insert 10 may
have one long tab centered on the longer portion of the rectangular main body,
as illustrated in
FIGS. 18 and 24-25. In another example, the insert 10 may have two long tabs,
wherein a first
tab is centered on the top edge of the longer portion of the rectangular body
and a second tab is
centered on the bottom edge of the longer potion of the rectangular body, as
illustrated in FIGS.
19. In a further example, the insert 10 may have a plurality of short tabs
that are evenly centered
around the middle of the longer portion of the body, wherein the short tabs
are located on the top
edge of the rectangular body, as illustrated in FIG. 20 or the top and bottom
edges of the
rectangular body, as illustrated in FIGS. 21 and 26-27. In another example,
the insert 10 may
have a combination of long and short tabs along the top and bottom edges of
the rectangular
body. For example, as illustrated in FIG. 22, the insert 10 may have short
tabs on the ends of the
top edge of the longer portion of the rectangular body and a long tab centered
on the top edge of
the longer portion of the rectangular body. As illustrated in FIGS. 23 and 28-
29, the insert 10
may have short tabs on the ends of the top and bottom edges of the longer
portion of the
rectangular body and long tabs centered on the top and bottom edges of the
longer portion of the
rectangular body.
Any of the configurations described above are conducive to adhesive tabs 34,
wherein the
adhesive tabs 34 fold over the edge of the suspension headband and attach to
the opposite side of
the suspension headband. For example, the embodiments with tabs on the top
edge of the
rectangular body can fold over the top edge of the suspension headband and
embodiments with
tabs on the top and bottom edges of the rectangular body can fold over the top
and bottom edges
of the suspension headband, respectively.
The configurations illustrated in FIGS. 24, 26, and 28 are conducive to hook
and loop
tabs 36, wherein the tab along the top part of the rectangular body can fold
over the suspension
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headband and either attach to a hook and loop portion on the rectangular body
itself, as
illustrated in FIG. 24, or to another tab along the bottom part of the
rectangular body, as
illustrated in FIGS. 26 and 28. In some embodiments of the hook and loop
configurations, the
rectangular body can have and adhesive layer 41 that also attaches to the
suspension headband.
The configurations illustrated in FIGS. 25, 27, and 29 are conducive to
snap/button tabs
38, wherein the tab along the top part of the rectangular body can fold over
the suspension
headband and either attach to a snap/button portion on the rectangular body
itself, as illustrated
in FIG. 25, or to another tab along the bottom part of the rectangular body,
as illustrated in FIGS.
27 and 29. In some embodiments of the snap/button configurations, the
rectangular body can
have and adhesive layer 41 that also attaches to the suspension headband.
Regardless of the headwear 20 to which the insert 10 attaches, the insert 10
may be
multilayer in construction. A top, moisture wicking layer 35, illustrated in
FIGS. 14-16,
contacts the user, is preferably moisture wicking, and may have a moisture-
absorbent
functional attribute to draw sweat away from the user. The moisture wicking
layer 35 can be
.. made of a hydrophilic material that functions to wick moisture from the
user's skin surface and
transfer it into the core of the product. The top, moisture wicking layer 35
may have an
embossed or printed pattern or logo. An inner layer, or core, is moisture
absorbent and may
have moisture retention attributes.
In some embodiments, the core may be formed from one layer of moisture
absorbent/retentive material. Alternatively, it may be formed from two or more
layers of such
material, as illustrated in FIGS. 13-16. These moisture absorbent/retentive
layers form the core
of the insert 10 and may be formed from non-woven materials including, for
example, non-
woven fluff, non-woven wood, wood pulp, wood pulp fibers, cotton, rayon, air
laid, paper or
non-woven absorbent polymeric fibers, other cellulosic materials, or the like.
For instance, in
one example, the core includes two layers that are moisture
absorbent/retentive layers. The first
layer can be made of a perforated non-woven material (e.g., spunlace)
material, and the second
layer can be an absorbent paper.
In another embodiment, as illustrated in FIG. 14, the core can contain three
layers,
wherein the first layer is a first, absorbent airlaid layer 37a, the second
layer is a super
absorbent polymer (SAP) layer 37b, and the third layer is a second, absorbent
airlaid layer
37c. As illustrated in FIG. 2, the second, super absorbent core layer 37b may
be generally
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rectangular in shape, while the first and second absorbent airlaid layers 37a,
37c take the
general shape of the insert 10. A fluid or liquid impervious layer 40 may also
be provided
(e.g., a polyethylene film) underneath the core to prevent fluid from
contacting the user's
forehead. In one embodiment, the type of materials used for feminine hygiene
pads may
suffice for the core. Therefore, the insert 10, in a preferred embodiment, has
a top, moisture
wicking layer 35, an absorbent core comprised of two, absorbent airlaid layers
37a, 37c that
sandwich a SAP layer 37b, and a liquid impervious layer 40.
In another embodiment, a fifth, adhesive layer 41 can attach to the liquid
impervious
layer 40. In this embodiment, the user can attach the disposable insert 10 to
headwear 20, such as
a helmet, hat, or hard hat. The adhesive layer 41 can be two-sided tape,
wherein one side faces
the liquid impervious layer 40 and the other side faces a sixth layer that is
a release liner 39 that
is removed before use. The adhesive layer 41 can also be hook and loop fabric.
The adhesive
layer 41 can be a full coverage adhesive layer, wherein it covers the entire
surface of the liquid
impervious layer 40, or it can be a partial coverage adhesive layer 41,
wherein it covers only a
portion of the liquid impervious layer 40. In some embodiments, however, there
is no adhesive
layer 41.
In some embodiments, the insert 10 can further include a foam material that is
moisture
wicking and that completely surrounds the absorbent core 37. The foam
material, in some
embodiments, can be porous. The moisture wicking foam layer can, in some
embodiments, be
.. poured, filled, or wrapped around the absorbent core 37. Alternatively, the
absorbent core 37
may be made of an absorbent foam material, wherein the absorbent core 37 is
one absorbent
foam layer entirely or is two or more absorbent foam layers. Alternatively,
the moisture wicking
foam can be a layer of foam, wherein one foam layer is included above the
absorbent core 37 and
a second foam layer is included below the absorbent core 37, thereby
sandwiching the core 37 in
moisture wicking foam. Similar to the layers described above, the second foam
layer located
below the absorbent core 37 can also be attached to an adhesive layer 41. The
adhesive layer 41
can, therefore, attach to the headwear 20, such as a hat, helmet, or hard hat.
Alternatively, the
insert 10 having first and second layers may be configured to form a band 50.
Therefore, the
insert 10 can be attached directly to the user's head by wrapping around the
head and securing
either by pressure (for example, if the band 50 is at least partially elastic)
or by attachment points
on the band 50.
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In some embodiments, a sealed perimeter 32 can be made when the perimeter of
at least
the top, moisture wicking layer 35, core layers 37, and liquid impervious
layer 40 are sealed
together, wherein the insert 10 has a continuous seal along the entire
perimeter. In some
embodiments, a sealed perimeter 32 can be made when the perimeter of at least
the top, moisture
wicking layer 35 and the liquid impervious layer 40 are sealed together, as
illustrated in FIGS. 2
and 18-30, wherein the insert 10 has a continuous seal along the entire
perimeter. In some
embodiments the type of material that is sealed is polypropylene,
polyethylene, hydrophilic
nonwoven, or other nonwoven material. The sealed perimeter 32 can be 1-3mm
thick and can be
created using means such as, but not limited to, construction glue and
pressure, heating element
seals (ex: hot bar, continuous, impulse), ultrasonic weld/seal/staking,
material welding and
bonding, sewing, transfer adhesives and pressure (ex: hot melts, construction
adhesives, or
transfer adhesives and tapes), high frequency welding, thermoplastic staking,
infrared staking,
radio frequency welding, laser welding, heat and pressure, or head seal
coating. In a preferred
embodiment, the sealed perimeter 32 is created using an impulse heating
element seal. Sealing
these layers together enables moisture to be locked in the core 37. In one
embodiment, the sealed
inner portion has a length L2 of between 8 and 9 inches (ex: 8.4629 inches)
and a width W2 of
between 2 and 3 inches (ex: 2.875 inches), as illustrated in FIG. 1.
In some embodiments, an impermeable gutter layer 45 may also be included in
the insert
10 or band 50, wherein the impermeable gutter layer 45 may be located under
the core layers 37
and act to pick up excess sweat that the core layers 37 cannot contain.
Therefore, the
impermeable gutter layer 45 acts as an impermeable barrier that keeps sweat
inside the insert 10
or band 50, and it can preferably be included in the insert 10 and band 50 if
there is no bottom,
liquid impervious layer 40. For example, as illustrated in FIG. 41, a band 50,
such as the band 50
illustrated in FIG. 32, may be comprised of a top, moisture wicking layer 35;
a top, elastic layer
43; core layers 37a, 37b, 37c; an impermeable gutter layer 45; and a bottom,
moisture wicking
layer 35.
The disposable absorbent insert 10 can be fitted against the front, inside
surface of
headwear 20, as illustrated in FIGS. 5-12 and 17. The insert 10 can also be
fitted against the
back, inside surface of headwear 20. In an alternative embodiment, as
illustrated in FIGS. 32-38,
the disposable insert 10 can be a band 50, such as, but not limited to, a
headband, wristband, or
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sweatband, and it can be positioned around a user's head without the need to
be adhered to
headwear 20, such as a helmet, hat, or hard hat.
In one embodiment, the device for absorbing and retaining sweat can be an
entirely
elastic band 50, as illustrated in FIGS. 32 and 33. In another example, the
device can be a band
50 that has at least a portion that is elastic 52 as well as an absorbent
portion 54, as illustrated in
FIGS. 34 and 35. In another embodiment, the device can be a band 50 that is
tied onto a user's
head, as illustrated in FIGS. 36-38. In this example, the band 50 can be
comprised of an
absorbent portion 56 and a tie portion 58 so that the user can tie the band 50
as tight as he or she
wishes. The band 50 functions to wick moisture away from the head of the user
and prevent
moisture from dripping down into the eyes, nose, mouth and overall facial area
of the user.
The band 50 can be in direct contact with the user's head and hair.
In some embodiments, the insert 10 or band 50 can be formed of an absorbent
material
and can be comprised of several layers, as illustrated in FIGS. 14-16. In one
embodiment, the
insert 10 or band 50 is comprised of a moisture wicking layer 35 that is in
contact with the
user's head when in use and wicks moisture away from the user's head.
Underneath the
moisture wicking layer 35 may be an absorbent core layer 37 that collects and
holds the
moisture that has been wicked away from the user's head. Underneath the
absorbent core
layer 37 may be a bottom, liquid impervious layer 40 that, along with the
moisture wicking
layer 35, encases the absorbent core layer 37 and prohibits moisture from
leaving the
absorbent core layer 37.
In some embodiments, underneath the bottom, liquid impervious layer 39 is a
pressure
sensitive adhesive layer 41 that covers the entire span of a bottom-side of
the bottom, liquid
impervious layer 40. In another embodiment, only a portion of the bottom,
liquid impervious
layer 40 is covered by the pressure sensitive adhesive layer 41. The pressure
sensitive adhesive
41 enables the insert 10 to adhere to the surface on the inside of the
headwear 20. The
adhesive of layer 41 is a repositionable pressure sensitive adhesive (and may
take the form
of double-sided tape), which allows insert 10 to be removed and discarded from
headwear 20
(or a suspension headband) without leaving adhesive residue. A removable
release liner layer
39 covers the adhesive layer 41 prior to use and is removed to expose the
adhesive layer
41 for mounting the insert 10 within the headwear 20. In one embodiment, the
release liner
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layer 39 is release paper. In another embodiment, the release liner layer 39
is a material with
silicon one or both sides of the release liner layer 39.
In some embodiments, as seen in FIGS. 13-16 and 39-42, the insert 10 or band
50 is
comprised of a moisture wicking layer 35 that is in contact with the user's
head when in use
and wicks moisture away from the user's head. Below the moisture wicking layer
35 is an
absorbent core layer 37 that is comprised of a top absorbent core layer 37a, a
middle, super
absorbent core layer 37b, and a bottom absorbent core layer 37c. The absorbent
core layer 37
collects and holds the moisture that has been wicked away from the user's
head. In some
embodiments, underneath the absorbent core layer 37 is a liquid impervious
layer 40 that,
along with the moisture wicking layer 35, encases the absorbent core layer 37
and prohibits
moisture from leaving the absorbent core layer 37. In some embodiments, an
additional, elastic
layer 43 is included that enables the insert 10 to have elasticity. Therefore,
in one example, the
insert 10 may have a top, moisture wicking layer 35; an absorbent core layer
37 comprised of a
top absorbent core layer 37a, a super absorbent core layer 37b, and a bottom
absorbent core
layer 37c; an elastic layer 43; a bottom, liquid impervious layer 40; and a
pressure-sensitive
adhesive layer 41, as illustrated in FIG. 42.
As described above, underneath the bottom, liquid impervious layer 40 can be a
pressure- sensitive adhesive layer 41 that covers part of, or the entirety of,
a bottom-side of
the bottom, liquid impervious layer 40, thus enabling the insert 10 to adhere
to the surface on
the inside of the head covering 20. The adhesive layer 41 may have a removable
release liner
layer 39 that covers the adhesive layer 41 prior to use and can be removed to
expose the
adhesive layer 41 for mounting.
In some embodiments, there is no liquid impervious layer 40, as illustrated in
FIGS. 39-
41. For example, one embodiment of the band 50, illustrated in FIG 39, is
comprised of five
layers: atop, moisture wicking layer 35; an absorbent core layer 37 comprised
of a top absorbent
core layer 37a, a super absorbent core layer 37b, and a bottom absorbent core
layer 37c; and a
second, moisture wicking layer 35.
In another example, one embodiment of the band 50, illustrated in FIG. 40, is
comprised
of seven layers: a top, moisture wicking layer 35; a first elastic layer 43;
an absorbent core layer
37 comprised of a top absorbent core layer 37a, a super absorbent core layer
37b, and a bottom
absorbent core layer 37c; a second elastic layer 43; and a second, moisture
wicking layer 35.
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In another example, one embodiment of the band 50, illustrated in FIG. 41, is
comprised
of seven layers: a top, moisture wicking layer 35; an elastic layer 43; an
absorbent core layer 37
comprised of a top absorbent core layer 37a, a super absorbent core layer 37b,
and a bottom
absorbent core layer 37c; a impermeable gutter layer 45; and a second,
moisture wicking layer
35.
In some embodiments, the moisture wicking layer 35, the liquid impervious
layer 40, or
both can incorporate flame-resistant fibers (e.g., Nomex by DuPont). In some
embodiments, the
device for absorbing and retaining sweat can include an absorption indicator
or a saturation
indicator, such as a color change indicator, wherein the color changes as more
sweat is absorbed,
and the change in color enables the user to know how much sweat the device has
absorbed and
about how much more it can absorb. In some embodiments, the absorption or
saturation indicator
can be a strip on the device. In one embodiment, the device can include glow
in the dark
materials so that the device is visible in darkness.
In some embodiments, in order to use the insert 10, the removable release
liner layer
39 is removed from the adhesive layer 41 by peeling it from the adhesive layer
41. The insert
10 is then applied to the headwear 20, either by applying it directly to
interior surfaces of
the headwear shell itself, or to a suspension headband shaped to conform to a
user's head.
The repositionable pressure sensitive adhesive of the adhesive layer 41 holds
the insert 10 in
place. The gaps 30 in the insert 10 facilitate bending of the insert 10 to
conform to the shape
of the headwear 20, as illustrated in FIGS. 5-12, and to prevent overlapping
of the material of
the insert 10. By preventing such overlap, a smooth surface of insert 10 lies
against the
user's head for increased comfort. After installation, the insert 10 can be
firmly secured to
the headwear 20 by the repositionable pressure sensitive adhesive 41, with the
exposed
surface of the insert 10 forming a contacting surface for the wearer of the
headwear 20.
After use, the insert 10 is easily removed by breaking the adhesive seal
between the insert 10
and the curved inside surface of the headwear 20.
In one embodiment, the insert 10 may be an absorbent cylinder that can be
elastic. The
cylinder can include three layers: a top layer, an airlaid layer, and a SAP
layer. The SAP layer
can be in the middle of the cylinder and the layers can be rolled up like a
tube. In one
embodiment, several cylinders or tubes can be intertwined or braided together
to make a larger
end product.
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In one embodiment, an insert 10 may contain one or more vents or cutouts that
are used
for ventilation and circulation. The vents or cutouts may be any shape, such
as, but not limited
to, a linear slit, a rectangle, a non-linear shape, an oval, etc. Further, the
edges of the vents or
cutouts may each have a sealed perimeter, similar to that described above.
Although the device for absorbing and retaining sweat disclosed herein has
been
described with respect to several embodiments, workers skilled in the art will
recognize that
changes may be made in form and detail without departing from the spirit and
scope of the
disclosure.
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