U.S. patent application number 15/294603 was filed with the patent office on 2017-04-20 for impact reduction apparel and impact absorbing liner for apparel.
The applicant listed for this patent is Impact Reduction Apparel, Inc.. Invention is credited to John Dana Chase, JR., George Octavio Flint, JASON WILLIAM HANCOCK.
Application Number | 20170105461 15/294603 |
Document ID | / |
Family ID | 58523368 |
Filed Date | 2017-04-20 |
United States Patent
Application |
20170105461 |
Kind Code |
A1 |
HANCOCK; JASON WILLIAM ; et
al. |
April 20, 2017 |
IMPACT REDUCTION APPAREL AND IMPACT ABSORBING LINER FOR APPAREL
Abstract
An impact absorbing liner apparatus and impact reduction apparel
are disclosed. An impact absorbing liner has a size and a
configuration, such as multiple extending impact absorbing members,
which can be formed and shaped around a part of a wearer's body.
The impact absorbing liner is at least partially obscured from
external view by apparel worn over the part of the wearer's body.
The apparatus further includes a rigid frame connected with the
impact absorbing liner and having at least a distal end and a
proximal end. The distal end and proximal end each have a
connection mechanism to connect together to provide the size and
the configuration for the impact absorbing liner, and to conform to
the impact reduction apparel.
Inventors: |
HANCOCK; JASON WILLIAM; (San
Diego, CA) ; Flint; George Octavio; (Encinitas,
CA) ; Chase, JR.; John Dana; (Encinitas, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Impact Reduction Apparel, Inc. |
Encinitas |
CA |
US |
|
|
Family ID: |
58523368 |
Appl. No.: |
15/294603 |
Filed: |
October 14, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62241696 |
Oct 14, 2015 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A42B 1/08 20130101; A42B
3/127 20130101; A41D 31/125 20190201; A41D 31/285 20190201; A41D
31/102 20190201; A42B 3/125 20130101 |
International
Class: |
A41D 13/015 20060101
A41D013/015; A41B 11/04 20060101 A41B011/04; A41D 13/05 20060101
A41D013/05; A41D 27/04 20060101 A41D027/04; A42B 3/12 20060101
A42B003/12; A41D 31/00 20060101 A41D031/00 |
Claims
1. A detachable impact absorbing liner for a hat, the detachable
impact absorbing liner comprising: an internal frame having a trunk
member extending from a frontal portion to a rear portion, and a
plurality of branch members extending laterally from the trunk
member, the plurality of branch members comprising a frontal branch
member and a rear branch member, at least two of the branch members
that extend from opposite sides of the trunk member having side
members extending laterally from a distal end of each of the at
least two of the branch members, the internal frame further
including a clasping system comprising a clasping mechanism on a
distal end of each of the side members and on a distal end of each
adjacent branch member of the plurality of branch members, the
clasping system enabling the internal frame to be shaped and
fastened in a semi-spherical shape to conform to a shape of a
wearer's head and to be positioned within the hat; two or more
impact resistant layers coupled with the internal frame, the two or
more impact resistant layers comprising a polymer layer having a
first density to resist puncture and tearing, and an inner impact
absorbing layer having a second density to resist impact, the two
or more impact resistant layers covering a majority of the internal
frame and being formed with cut-ins to allow the two or more impact
resistant layers to conform to the shape of the wearer's head when
the internal frame is shaped and fastened in the semi-spherical
shape.
2. The detachable impact absorbing liner in accordance with claim
1, wherein the two or more impact resistant layers include a
breathable, moisture-wicking fabric attached to the inner impact
absorbing layer.
3. The detachable impact absorbing liner in accordance with claim
1, wherein the internal frame is interposed between the polymer
layer and the inner impact absorbing layer.
4. The detachable impact absorbing liner in accordance with claim
1, wherein the internal frame is formed of polycarbonate.
5. The detachable impact absorbing liner in accordance with claim
1, wherein the two or more impact resistant layers include a
plurality of aeration holes.
6. The detachable impact absorbing liner in accordance with claim
1, wherein the inner frame includes a set of channels formed in the
trunk member and/or in one or more of the plurality of branch
members.
7. The detachable impact absorbing liner in accordance with claim
1, further comprising an attachment mechanism for attaching the
impact absorbing liner to an internal cavity of the hat.
8. The detachable impact absorbing liner in accordance with claim
1, further comprising an additional internal frame, where two or
more impact resistant layers are disposed between the two internal
frames.
9. The detachable impact absorbing liner in accordance with claim
1, further comprising a chin strap configured to secure the
detachable impact absorbing liner to the wearer's head.
10. The detachable impact absorbing liner in accordance with claim
1, further comprising an outer encapsulation device having cover
portions attached to the two or more impact resistant layers and
internal frame with one or more elastic bands.
11. A detachable impact absorbing liner for an item of apparel, the
detachable impact absorbing liner comprising: an internal frame
having a trunk member extending from a first portion to a second
portion opposite the first portion, and a plurality of branch
members extending laterally from the trunk member, the plurality of
branch members comprising a first end branch member and a rear end
branch member, at least two of the branch members that extend from
opposite sides of the trunk member having side members extending
laterally from a distal end of each of the at least two of the
branch members, the internal frame further including a clasping
system comprising a clasping mechanism on a distal end of each of
the side members and on a distal end of each adjacent branch member
of the plurality of branch members, the clasping system enabling
the internal frame to be shaped and fastened in a shape to conform
to a shape of a wearer's body part and to be positioned within an
item of apparel; two or more impact resistant layers coupled with
the internal frame, the two or more impact resistant layers
comprising a polymer layer having a first density to resist
puncture and tearing, and an inner impact absorbing layer having a
second density to resist impact, the two or more impact resistant
layers covering a majority of the internal frame and being formed
with cut-ins to allow the two or more impact resistant layers to
conform to the shape of the wearer's body when the internal frame
is shaped and fastened in the shape conforming to the wearer's
body.
12. The detachable impact absorbing liner in accordance with claim
11, wherein the two or more impact resistant layers include a
breathable, moisture-wicking fabric attached to the inner impact
absorbing layer.
13. The detachable impact absorbing liner in accordance with claim
11, wherein the internal frame is interposed between the polymer
layer and the inner impact absorbing layer.
14. The detachable impact absorbing liner in accordance with claim
11, wherein the internal frame is formed of polycarbonate.
15. The detachable impact absorbing liner in accordance with claim
11, wherein the two or more impact resistant layers include a
plurality of aeration holes.
16. The detachable impact absorbing liner in accordance with claim
11, wherein the inner frame includes a set of channels formed in
the trunk member and/or in one or more of the plurality of branch
members.
17. The detachable impact absorbing liner in accordance with claim
11, further comprising an attachment mechanism for attaching the
impact absorbing liner to an internal cavity of the item of
apparel.
18. The detachable impact absorbing liner in accordance with claim
11, wherein the item of apparel is a sock and where the clasping
system causes the internal frame to be shaped and fastened in a
shape to conform with a shin of the wearer.
19. The detachable impact absorbing liner in accordance with claim
11, where the item of apparel is underwear and where the clasping
system causes the internal frame to be shaped and fastened in a
shape to conform with a pelvic region of the wearer.
20. A detachable impact absorbing liner for an item of apparel, the
detachable impact absorbing liner comprising: a frame having a
central portion and fingers extending from the central portion, the
fingers having clasping members extending substantially laterally
away from the end portions of the fingers, the clasping members
configured to clasp with clasping members of adjacent fingers, the
frame configured such that when clasped the frame conforms to the
shape of a wearer's body part; two or more impact resistant layers
coupled with the frame, the two or more impact resistant layers
comprising a polymer layer having a first density to resist
puncture and tearing, and an inner impact absorbing layer having a
second density to resist impact, the two or more impact resistant
layers covering a majority of the frame and being formed with
cut-ins to allow the two or more impact resistant layers to conform
to the shape of the wearer's body part when the frame is shaped and
fastened in shape conforming with the wearer's body part.
21. The impact absorbing liner in accordance with claim 11, where
additional coverage for the occipital lobe, as applied to ball caps
or other headgear equipment, can aid in securing the garment to the
wearer and offer increased coverage area.
22. The impact absorbing liner in accordance with claim 11, where
additional coverage for the temporal lobe, as applied to ball caps
or other headgear equipment, can aid in securing the garment to the
wearer and offer increased coverage area.
23. The impact absorbing liner in accordance with claim 1, further
comprising a mechanical fastener that allows rotation about a
pivotal axis for access between the liner and apparel.
24. The impact absorbing liner in accordance with claim 1, further
comprising a mechanical attachment applied to further secure
headgear to the users body and may be applied either under the
wearers chin or behind the head.
Description
RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of U.S.
Provisional Patent Application No. 62/241,696 filed Oct. 14, 2015,
which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] Just about every activity requires apparel, and sometimes
very specific apparel, such as helmets and pads for skateboarders,
in addition to standard shirts, shoes, pants, shorts, socks or any
coverage that has potential for impact. Surfers often wear
wetsuits. Skiers and snowboarders often wear helmets, while a
number of snowboarders wear additional protection such as knee pads
and wrist guards. As used herein, the term "apparel" refers not
only to clothing, headgear or footwear, but also to accessories
that can be worn by a person separately or with such clothing,
headgear or footwear or legwear. Additionally, "apparel" refers to
any covering for areas of impact on equipment or devices.
[0003] However, common impact reduction apparel, coverings or
accessories are typically very bulky, cumbersome, and stand out too
much for the tastes of their wearer. Thus, many people in certain
activities will opt to not use any impact resistant products,
which, while appearing more fashionable, put them at increased risk
of injury from an impact while undergoing the activity. For
example, skateboarders often eschew helmets in favor of trendy hats
such as ball caps, beanies or trucker's hats. These hats provide
nearly zero impact reduction.
[0004] For equipment applications, despite precautions and robust
designs, the risk of an accidental impact is apparent and can be
detrimental to the equipment's proper function. Shipping and
storage of sensitive and fragile equipment can be an area of risk
and is well suited for alternative coverings to avoid and minimize
damage.
[0005] Accordingly, what is needed is impact reduction apparel that
can be worn with other apparel, placed over sensitive equipment,
and have a low profile, subtle appearance or be hidden altogether.
Further, such impact reduction apparel can provide a platform for
features that were previously impossible or very difficult to
implement with conventional apparel.
SUMMARY
[0006] An impact absorbing liner for existing and custom apparel or
other equipment is presented, as is apparel or accessories
integrating such impact absorbing liner. The impact absorbing liner
includes one or more layers of impact absorbing and/or abrasion
resistant material. Each layer of impact absorbing material is
sized and configured to be positioned over one or more critical
areas of a wearer's body, which may be exposed to a risk of impact
during an activity, lifestyle or equipment lifecycle. The impact
absorbing liner further includes one or more connectors, for
connecting various parts of the impact absorbing liner together and
allowing the connection to be sized to fit any particular
application. Each layer has a specific material designed for
optimum comfort and impact reduction, abrasion resistance and
overall product integrity.
[0007] Creases and peripheral profiles are configured to enable
flat packaging and folding for storage when product is not in use.
The impact absorbing liner can be formed to a unique profile that
will conform to the inside of another piece of apparel or
accessory, such as inside the user's headgear, or other
head-covering equipment. A thin impact absorbing liner can be
applied in strategic locations to reduce the risk of damage to
apparel and equipment without the need for bulky apparatuses. The
impact absorbing liner can be removable and used in several
garments or can be permanently integrated into an apparel or
equipment product.
[0008] One aspect of the present disclosure relates to a detachable
impact absorbing liner for an item of apparel. The detachable
impact absorbing liner may comprise an internal frame. The internal
frame may have a trunk member. The trunk member may extend from a
first portion to a second portion opposite the first portion. The
trunk member may include a plurality of branch members extending
laterally from the trunk member. The plurality of branch members
may comprise a first end branch member and a rear end branch
member. At least two of the branch members that extend from
opposite sides of the trunk member may have side members extending
laterally from a distal end of each of the at least two of the
branch members. The internal frame may further include a clasping
system. The clasping system may comprise a clasping mechanism on a
distal end of each of the side members and on a distal end of each
adjacent branch member of the plurality of branch members. The
clasping system may enable the internal frame to be shaped and
fastened in a shape to conform to a shape of a wearer's body part
and to be positioned within an item of apparel for that body
part.
[0009] The detachable impact absorbing liner for an item of apparel
comprising two or more impact resistant layers. The two or more
impact resistant layers may be coupled with the internal frame. The
two or more impact resistant layers may comprise a polymer layer.
The polymer layer may have a first density to resist puncture and
tearing. The two or more impact resistant layers may comprise an
inner impact absorbing layer having a second density to resist
impact. The two or more impact resistant layers may cover a
majority of the internal frame. The two or more impact resistant
layers may be formed with cut-ins. The cut-ins may allow the two or
more impact resistant layers to conform to the shape of the
wearer's body when the internal frame is shaped and fastened in the
shape conforming to the wearer's body.
[0010] In some variations the item of apparel may be a sock. The
clasping system may cause the internal frame to be shaped and
fastened in a shape to conform with a shin of the wearer. The item
of apparel may be underwear. The clasping system may cause the
internal frame to be shaped and fastened in a shape to conform with
a pelvic region of the wearer.
[0011] One aspect of the present disclosure relates to a detachable
impact absorbing liner for an item of apparel. The detachable
impact absorbing liner may comprise a frame. The frame may have a
central portion. The frame may have fingers. The fingers may extend
from the central portion. The fingers may have clasping members
extending substantially laterally away from the end portions of the
fingers. The clasping members may be configured to clasp with
clasping members of adjacent fingers. The frame may be configured
such that when clasped the frame conforms to the shape of a
wearer's body part.
[0012] The detachable impact absorbing liner for an item of apparel
may comprise two or more impact resistant layers. The two or more
impact resistant layers may be coupled with the frame. The two or
more impact resistant layers may comprise a polymer layer having a
first density to resist puncture and tearing. The two or more
impact resistant layers may comprise an inner impact absorbing
layer. The inner impact absorbing layer may have a second density
to resist impact. The two or more impact resistant layers may cover
a majority of the frame. The two or more impact resistant layers
may be formed with cut-ins to allow the two or more impact
resistant layers to conform to the shape of the wearer's body part
when the frame is shaped and fastened in shape conforming with the
wearer's body part.
[0013] In some variations, the impact reducing liner can be
permanently integrated into the headgear, hat, head covering
equipment, apparel, garment or the like. One or more impact
reducing liners can be applied to apparel or an accessory to cover
strategic areas as needed for a given application. Relief cuts can
be applied in areas where flex and conformity is needed for proper
function. Relief cuts can allow for improved conformity of the
insert to the wearer's head or body. In some implementations, one
or more impact resistant liners as described herein can be affixed
to a hat or garment through pockets, stitching, hook and loop
fasteners, adhesive, mechanical fasteners, rivets, or the like.
Attachment methods can be applied to allow for removal of the
impact resistant liner(s) for cleaning or maintenance or be
intended as a permanent application.
[0014] In exemplary headgear applications a liner may be secured
with a polymer tab for integration onto a central button or
cylindrical device on the crown of said headgear. A polymer tab
provides a rigid platform to secure a liner onto hat or garment
through pockets, stitching, hook and loop fasteners, adhesive,
mechanical fasteners, rivets, or the like. The tab may also allow
free rotation about a pivotal axis to relocate the attached liner
for a variation of applications. Such applications may include
embroidery, cleaning, maintenance, additional components or the
like.
[0015] The total number of inserts may vary to suit the need of
specific application requirements. One exemplary application may
yield a seam or gap in a designated location which allows for easy
folding of the hat, garment or device for storage, shipping or
other application needs.
[0016] The details of one or more embodiments are set forth in the
accompanying drawings and the description below. Other features and
advantages will be apparent from the description and drawings, and
from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] These and other aspects will now be described in detail with
reference to the following drawings.
[0018] FIG. 1 is a section view of an impact absorbing liner with
aeration holes;
[0019] FIG. 2 is an isometric view of an impact absorbing liner
with flex/vent grooves;
[0020] FIG. 3 is a detailed view of the flex/vent grooves of an
impact absorbing liner;
[0021] FIG. 4 is a plan view of an impact absorbing liner showing
aeration holes;
[0022] FIG. 5 illustrates an adjustable clasp;
[0023] FIG. 6 illustrates an internal frame of an impact absorbing
liner, inside looking out;
[0024] FIG. 7 illustrates an internal support structure of an
impact absorbing liner;
[0025] FIG. 8 illustrates another internal support structure of an
impact absorbing liner;
[0026] FIG. 9 illustrates a close-up view of a snap-fit detail of
the internal support structure of an impact absorbing liner;
[0027] FIG. 10 is a plan view of an impact absorbing liner, inside
looking out;
[0028] FIG. 11 is a transparent view of the assembly showing an
integral internal frame;
[0029] FIG. 12 is an assembly view of an impact absorbing liner
showing a close-up of a snap closure with adjustable features;
[0030] FIG. 13 is an isometric view of an assembly of an impact
absorbing liner, inside looking out;
[0031] FIG. 14 is another isometric view of the assembly;
[0032] FIG. 15 is a plan view of the assembly of an impact
absorbing liner, outside looking in;
[0033] FIG. 16 is an isometric section view showing integral
internal structure within an impact absorbing liner;
[0034] FIG. 17 illustrates a rear view of an impact absorbing
liner;
[0035] FIG. 18 illustrates a top view of an impact absorbing
liner;
[0036] FIG. 19 illustrates another top view of an impact absorbing
liner;
[0037] FIG. 20 illustrates arcs positioned on the outside profile
for full coverage by an impact absorbing liner when installed, and
also illustrates temple protection;
[0038] FIG. 21 illustrates integrated drawstring tubes;
[0039] FIG. 22 illustrates an integrated clasp for snap-back and
strap back hats;
[0040] FIG. 23 is an exploded view of a layered configuration of an
impact absorbing liner for headgear applications;
[0041] FIG. 24 is a two-dimensional profile showing an external
shape and internal relief cuts;
[0042] FIG. 25 illustrates a headgear application as installed on a
representative head. Relief cuts placed at areas of curvature to
enable conformity to the surface; and
[0043] FIG. 26 is an exploded view of the base materials of an
impact absorbing liner for lamination and prior to cutting
parts.
[0044] FIG. 27 is an isometric view of an outer encapsulation
device for an impact absorbing liner
[0045] FIG. 28 is an isometric view of an outer encapsulation
device
[0046] FIG. 29 is an impact absorbing insert
[0047] FIG. 30 is a view of an exemplary liner insert profile with
relief features
[0048] FIG. 31 is a view of a liner insert attached to a textile
with margin for secondary attachment methods.
[0049] FIG. 32 is an exemplary view of a headgear application with
impact reduction padding infused into the base textile.
[0050] FIG. 33 is an exemplary view of the inside of a hard shell
headgear application
[0051] FIG. 34 is a view of an insert for hard shell headgear
applications showing representative relief cuts and profile
adaptations.
[0052] FIG. 35 is a view of an insert for hard shell headgear
applications showing representative profile adaptations.
[0053] FIG. 36 is a view of an insert for hard shell headgear
applications showing representative profile adaptations.
[0054] FIG. 37 is a view of an insert for hats showing
representative relief cuts and profile adaptations for the front
panel
[0055] FIG. 38 is a view of an insert for hats showing
representative relief cuts and profile adaptations for the side
panel
[0056] FIG. 39 is a view of an insert for hats showing
representative relief cuts and profile adaptations for the back
panel
[0057] FIG. 40 is an isometric view of a ball cap showing a
representative chin strap adaptation
[0058] FIG. 41 is an isomeric view showing a representative clip to
secure a chin strap to headgear.
[0059] FIG. 42 is an isometric view showing a close up of a
representative clip to secure a chin strap before it is installed
into a hat
[0060] FIG. 43 is an isometric view showing a close up of a
representative clip and chin strap assembly joint before it is
installed into a hat
[0061] FIG. 44 is an isometric view of a hat showing a
representative installation adaptation for a chin strap loop
between the sweatband and the outer fabric of a hat
[0062] FIG. 45 is an isometric view showing a representative
adaptation of padded taping as typically applied on ball caps
[0063] FIG. 46 is an isometric view showing a representative padded
taping before installation onto hat or garment
[0064] FIG. 47 is a view of an exemplary liner insert profile for
front and side coverage with relief features
[0065] FIG. 48 is a view of a representative component to align and
secure a liner while allowing free rotation
[0066] FIG. 49 is an exemplary view of a liner installed in a ball
cap to provide front and side coverage
[0067] FIG. 50 is an exemplary view of a one piece liner secured
into a representative headgear while allowing for rotation
[0068] FIG. 51 is an exemplary view of a liner installed in a ball
cap and rotated 180 degrees to provide access to the front of the
hat for embroidery or other customization
[0069] FIG. 52 demonstrates the components of an embodiment to
secure in a hat or headgear through an exploded assembly view
[0070] FIG. 53 is a view of an exemplary liner insert for a 2 piece
configuration; front insert shown
[0071] FIG. 54 is a view of an exemplary liner insert for a 2 piece
configuration; back insert shown
[0072] FIG. 55 is an exemplary view of a 2 piece liner system
installed in a ball cap
[0073] FIG. 56 is an exemplary view of a representative headgear
with a dropdown secion in the back for additional coverage on the
users head
[0074] FIG. 57 is an exemplary view of a 2 piece liner system
installed in a ball cap with only the back panel shown
[0075] FIG. 58 is an exemplary view of a 2 piece liner system
installed in a ball cap with only the front panel shown
[0076] FIG. 59 is an exemplary view of a 2 piece liner system
installed in a ball cap and folded for shipping, storage or other
applications
[0077] FIG. 60 is an isometric view representing a securing strap
which wraps below the ears and around the back of the users
head
[0078] FIG. 61 is an exemplary view of a securing strap which wraps
below the ears and around the back of the users head installed on a
representative headgear
[0079] FIG. 62 is an isometric view of a securing strap installed
on a representative headgear with internal attachment mechanism
shown in dotted lines
[0080] FIG. 63 is a view representing an exemplary configuration of
a wraparound strap in a collapsed position when not in use
[0081] Like reference symbols in the various drawings indicate like
elements.
DETAILED DESCRIPTION
[0082] This document describes an impact absorbing liner for
existing and custom apparel and equipment. In one example, the
apparel is headgear, such as a baseball cap or "trucker's cap" or
beanies. The impact absorbing liner includes one or more layers of
impact absorbing material. Each layer of impact absorbing material
is sized and configured to be positioned over critical areas of a
wearer's body, such as, but not limited to, parts of a wearer's
head, which may be exposed to a risk of impact during an active
lifestyle. The impact absorbing liner further includes one or more
connectors, for connecting various parts of the impact absorbing
liner together after the liner has been formed to confirm to the
critical areas of the wearer's body, and allowing the liner to be
sized to fit any particular application. One or more of the
connectors can be self-adhering, or may have a connection mechanism
such as a mechanical clasp (snap, button, zipper, Velcro, etc), or
other mechanism.
[0083] The impact absorbing liner is wearable with other apparel or
devices such that the impact absorbing liner is hidden or
hide-able. The impact absorbing liner combines aesthetic design
with impact protection, and can have one or more size adjustment
mechanisms to allow for a universal fit.
[0084] In some implementations, the layers of impact absorbing
material are rigid or semi-rigid, and can be made of so called
"smart molecules" that harden on impact, open cell urethane foam
rubber, closed cell urethane foam rubber, silicone elastomer,
polycarbonate, Kevlar, textiles or the like, and formed to be worn
with into custom and existing head gear or to fit a unique profile
needed for a specific application. Accordingly, the impact
absorbing liner combines aesthetic design with impact
protection.
[0085] In a headgear application, the impact absorbing liner can be
formed and shaped to fit at least partially or even completely
within, various headgear such as helmets, hard hats, headbands,
sweatbands, hoodies, beanies, skull caps, wigs, ballcaps (fitted,
stretch-fit and adjustable), wetsuit caps, dry suit caps, scuba
diving caps and hiking headgear. Other headgear and apparel can be
used.
[0086] Other apparel applications include, but not limited to,
temple protection (right or left as needed for batting and pitching
applications), ear covers, elbow pads, t-shirts (long and short
sleeve), sweaters, sweatshirts, undergarments (boxers, briefs,
sports bra), booties, shirt or jersey with integrated sports bra,
gloves, mittens, jeans, head socks (for positioning under helmet or
the like), hiking boots, work-boots, designer boots, shoes, tennis
shoes, running shoes, cleats, golf shoes, snowboarding boots, ski
boots, socks with integrated padding in the shin, ankle or
surrounding area, shin pads, ankle guards, or the like.
[0087] Applications of the impact absorbing liner can include
equipment and commercial applications such as, without limitation,
soccer shin guards, backpack, luggage, medical braces, casts,
bandages, medical wraps, wrist guards, metatarsal insert, sole
inserts, carpet padding, carpet, area rugs, blankets, seat covers,
interior car side paneling, sensitive electronic cabinets, storage
boxes, military communication systems, radar components, sonar
components or the like. Regardless of application, the impact
absorbing liner can be manufactured and shipped flat to minimize
warehousing requirements for high volume applications or molded to
specific form as required.
[0088] Impact Absorbing Liner:
[0089] In exemplary implementations, the impact absorbing liner can
be designed to be integral with a headgear article, or removable to
meet a variety of application requirements. The impact absorbing
liner can be formed to stand freely on its own in a shape desired
for end use. The impact absorbing liner can be configured to lay
flat for streamlined packaging and shipping before use. The impact
absorbing liner can be made from one or more layers of a variety of
impact absorbing materials such as open cell urethane foam rubber,
closed cell urethane foam rubber, silicone elastomer, Kevlar,
polycarbonate or alike, and which can be formed of any thickness,
density and profile to provide maximum impact resistance while
remaining thin, light weight and low profile. The material can
maintain elasticity, which can then be used as a fine adjustment
and as a security feature to hold the impact absorbing liner in a
desired position when in use.
[0090] FIGS. 1-63 illustrate exemplary implementations of the
disclosed technology. In some exemplary implementations, as
illustrated in FIGS. 1-63, an impact absorbing liner is provided
for application to headgear. The headgear can include, without
limitation, ball caps, beanies, hoodies, military style hats,
equestrian hats, or the like. The impact absorbing liner can be
either universal or one-sized, or custom designed for specific
applications. For instance, snap back and fitted ball caps may both
use one common size and design or vary as needed.
[0091] FIG. 1 is a cut-away section view of an impact absorbing
liner 100 with aeration holes 102. The impact absorbing liner 100
includes cut-in sections 104 that define laterally-extending arms
106 or coverage regions 108 of the one or more layers of impact
absorbing materials. FIG. 2 is an isometric view of an impact
absorbing liner 200 with flex/vent grooves 202 that are formed into
the one or more layers of impact absorbing materials. In some
instances, the flex/vent grooves 202 can be used in addition to, or
in lieu of, the aeration holes 102 through the impact absorbing
liner 100. FIG. 3 is a detailed view of flex/vent grooves 302 of an
impact absorbing liner 300, consistent with that shown in FIG. 2.
Each flex/vent groove 302 can be formed into one or more of the
layers of impact absorbing materials, preferably leaving at least
one layer of the material intact.
[0092] FIG. 4 is a plan view of an impact absorbing liner 400 with
aeration holes 402, and illustrating a preferred cut-out shape of
the impact absorbing liner 400 in an un-assembled form, i.e. as cut
with a die or pressed from a mold for shipping and prior to being
formed into a semi-spherical shape to be worn as an impact
absorbing liner for a piece of headgear, such as a hat or cap. The
aeration holes 402 can be applied as needed based on a desired
breathability of the selected material. If a solid gel elastomer is
used, aeration holes can be applied to provide adequate ventilation
and avoid overheating the user. Conversely, if a breathable open
cell foam material is applied, the material itself will provide
breathability and maximize the available surface area for the
absorbing material.
[0093] FIG. 5 illustrates a portion of an internal frame having a
fastening device such as an adjustable clasp 500 with recess 501 to
allow for a flat assembly. Fasteners 502, which can be snaps,
clasps, pins and corresponding holes, or the like, provide a
mechanism with which to attach the frame creating and maintaining a
curved shape. Slots 503 eliminate material where it is not needed
for performance and allow reduced weight for the final assembly.
The, adjustable clasp 500 may or may not be integral with the
structural frame, and provides a foundation to fasten the entire
assembly together. In some implementations, the adjustable clasp
500 can have a range of adjustability to cover the full range of
adult and children sizes. In some implementations, the adjustable
clasp 500 includes a snap-fit clasp that allows for easy adjusting
while providing a secure closure. Elastic straps and or hook and
loop fasteners can also be used in strategic locations, such as
slots 503, to allow for a snug, universal fit of the impact
absorbing liner, via adjustment of the structural frame, as
needed.
[0094] FIG. 6 illustrates an internal frame 600 of an impact
absorbing liner, inside looking out. First fasteners 601 secure the
frame to maintain lateral shape and secure to the wearer's head.
Second fasteners 602 secure the internal frame 600 to maintain
circumferential shape and allow adjustability to secure to various
head shapes and sizes. First and second fasteners 601 and 602
enable adjustments necessary to make the product universal to fit a
range of head shapes and sizes.
[0095] FIG. 7 illustrates an isometric view of an internal frame
700 to provide a support structure of an impact absorbing liner.
FIG. 8 illustrates a plan view of an internal frame 800 of an
impact absorbing liner. The internal frame 700 or 800 can be formed
of, without limitation, one or more of polycarbonates, Kevlar,
fiberglass, polyethylene, polypropylene, vinyl, or the like and
which provides puncture and abrasion resistance in addition to
structural support for a self-supporting product. The internal
frame 700, 800 also allows for a wider range of liner materials.
For instance, using soft liner materials without an internal frame
may weaken the assembly and hinder protection due to the liner
material shifting around instead of staying in position.
[0096] The internal frame 700, 800 can be formed to spring out and
conform to the shape of the apparel within which it is placed as
needed to suit the specific application. Additionally, the internal
frame 700, 800 can be pre-formed, using thermoforming or similar
press process, to create a unique shape to which the softer, impact
absorbing layers will conform. This provides a stable and
standalone structure with a secure and contoured fit into the
receiving apparel. By using the internal frame 700, 800, the
assembly can be either removable or integrated within the impact
absorbing liner during manufacturing. The internal frame 700, 800
also provides a base or foundation for the adjustable clasp for the
user to easily store the impact absorbing liner when not in use and
in a flattened configuration, for quick assembly when needed. The
adjustable clasp also provides a mechanism to securely attach the
liner to the area requiring protection.
[0097] In some implementations, the internal frame 700, 800 can
include a locating hole to provide alignment points for use during
over mold or assembly of the liner during the manufacturing
process. These holes, in conjunction with the adjustable clasp, can
ensure proper alignment of the assembly during manufacturing. The
internal frame 700, 800 can be collapsible or manufactured in
multiple parts to allow for quick folding and storage of the impact
absorbing liner when traveling, shipping or not in use.
[0098] The internal frame 700, 800 adds an additional layer of
protection to resist against punctures in strategic locations. The
internal frame 700, 800 can also have thicker sections or multiple
layers at strategic locations on the frame. Outer edges can be
raised or corrugated to achieve the desired rigidity while
minimizing added weight. The internal frame 700, 800 can also
provide an alternative path for impact load dispersion. Instead of
an impact being focused on the immediate contact area, the internal
frame 700, 800 can act as a dispersion element and help absorb and
dissipate the force.
[0099] In addition to thickness variations, the material properties
can also be varied throughout the internal frame 700, 800.
Inserting sections with higher elasticity properties, the
versatility and adjustment of the frame is increased. The amount of
mechanical adjustment needed can be reduced and replaced with
elastic allowances and impact absorbing qualities in the material
itself. Some applications may also require a more rigid section for
either support or increased protection. This property can also be
varied during internal frame manufacturing.
[0100] The internal frame 700, 800 can be formed or manufactured in
various colors and textures to suit the branding and marketing
demands. Color variations can be custom suited to various logos,
applications and styles. Transparent and opaque shades can also be
used for either demonstration purposes or for aesthetic reasons as
needed. Texture can be varied as well to suit the specific
application. Some textures will be better suited for adding layers
or material, covering in cloth or other casing than textures used
with the raw base material and inside another hat or garment. The
internal frame 700, 800 can be made of a rigid or semi-rigid
plastic, polycarbonate, polyethylene, polypropylene, vinyl, carbon
fiber, a metal mesh, or metal wire, or the like.
[0101] The internal frame 700, 800 need not be "internal" to other
layers of the impact absorbing liner, and can be applied to either
exterior surface of the impact absorbing liner. This configuration
can be applied in addition to the internal frame 700, 800 as
mentioned herein and can serve to act as a hard shell for
protection and rigidity. As an external frame, the frame can be
made up of multiple sections to allow for increased flexibility.
Each section can be mechanically attached and either be applied as
a single piece or as multiple pieces. Multiple pieces of the frame
can be hinged or connected together in a chain configuration where
the rotational axis is aligned accordingly to provide flexibility
in the desired direction and limit movement as needed.
[0102] FIG. 9 illustrates a close-up view of a snap fit of the
internal frame 900 of an impact absorbing liner, in accordance with
some implementations, and as substantially described above.
[0103] FIG. 10 shows a plan view of an assembled impact absorbing
liner 1000, inside looking out. Undercut 1001, 1002 and 1003 allow
space to accommodate for the thickness of a sweat band and maximize
fit and comfort when inserted into a hat, for example. Adjustable
clasp mechanisms 1004 and 1005 extend from the various extending
members for allowing a customized fit. FIG. 11 is a transparent
view of the assembly showing an integral internal frame 1100, and
shows the over mold of the frame and the impact absorbing
liner.
[0104] FIG. 12 is an assembly view 1200 of an impact absorbing
liner showing a close-up of a snap closure with adjustable
features. FIG. 13 is an isometric view of an assembly 1300 of an
impact absorbing liner with integral support frame, from the inside
looking out. FIG. 14 is another isometric view of an assembly 1400,
from the outside looking in. FIG. 15 is a plan view of an assembly
of an impact absorbing liner 1500, from the outside looking in.
[0105] FIG. 16 is an isometric section view showing integral
internal structure within an impact absorbing liner 1600. The
impact absorbing liner 1600 includes an internal frame having
extending frame arms 1601 and 1602.
[0106] FIG. 17 illustrates a rear view of an impact absorbing liner
1700 as installed on the wearer's head. FIG. 18 illustrates a top
view of an impact absorbing liner 1800 as installed on the wearer's
head. FIG. 19 illustrates another top view of an impact absorbing
liner 1900, in an assembled state.
[0107] FIG. 20 illustrates a side view (left side shown) of a
folded impact absorbing liner 2000 and 2002. Temple protection 2001
can be fitted on the left or right side (left side shown). Arcs
2003 and 2004 fold and conform to mating curvature for full
coverage when installed.
[0108] FIG. 21 illustrates integrated drawstring tubes (dotted
lines) 2100. An integrated drawstring tube is represented within an
impact absorbing liner placed in the front band, 2101, and side
bands, 2102, of the product.
[0109] FIG. 22 illustrates a close up isometric view of the back of
an impact absorbing liner 2200. An integrated clasp 2201 for
snap-back and strap back hats maintains proper alignment and secure
attachment when installed into a hat. Drawstring tube in the side
band 2202 is further described in FIG. 21.
[0110] FIG. 23 is an exploded view of a layered configuration 2300
of an impact absorbing liner 2301 for headgear applications
(additional layers can be applied) or other applications as needed.
The impact absorbing liner 2301 includes a polymer layer 2302 to
disperse impact loads and maintain structural integrity of the
assembly. The polymer layer 2302 also resists puncture and tearing
of the assembly. The impact absorbing liner 2301 further includes
an inner impact absorbing layer 2303, and a breathable, moisture
wicking fabric 2304.
[0111] FIG. 24 is a two-dimensional profile of an impact absorbing
liner 2400 showing an external shape and internal relief cuts. The
impact absorbing liner 2400 includes a back band 2401 that rests
either inside of a sweatband of a hat, inside of a clasp on snap
back hats or the like. The impact absorbing liner 2400 further
includes a back ear member 2402 that provides extended coverage
over the head with a tailored profile to offer a seamless
transition between the back and side bands. Side band 2403 rests
either inside of a sweatband of a hat or other method of securing
in place. Side arm 2404 extends from the center portion of the
product and connects the side band. Front ear member 2405 offers
extended coverage over the head with a tailored profile to offer a
seamless transition between the front and side bands. Front band
2406 rests either inside of a sweatband of a hat or other method of
securing in place. This portion rests between the bill of a ball
cap and the wearer's head. The front band offers coverage of the
lower portion of the wearer's head and provides a mating edge for
the front ear to provide maximum coverage. Undercut grooves 2407 to
resist tearing and enhance movement when folded into a
hemispherical shape as when worn on the head. The grooves shown are
merely representative, and can be positioned throughout as needed
to maximize folding effectiveness and coverage.
[0112] FIG. 25 illustrates a headgear application as installed on a
representative head 2500. Relief cuts 2501 placed at areas of
curvature to enable conformity to the surface. Remaining features
as further described in FIG. 20.
[0113] FIG. 26 is an exploded view of the base materials of an
impact absorbing liner 2600 for lamination and prior to cutting
parts. The impact absorbing liner 2600 includes a cloth or
performance fabric layer 2601, and an inner impact absorbing layer
2602. The impact absorbing liner 2600 further includes a polymer
based semi rigid structural liner 2603. This liner provides lateral
support, abrasion resistance and puncture resistance in addition to
impact dispersion attributes. The impact absorbing liner 2600
further includes an outer impact absorbing layer 2604. Additional
layers and combinations of polymer and impact absorbing materials
can be applied as needed for a desired application.
[0114] FIG. 27 is an isometric view of an outer encapsulation
device 2700 to support an impact absorbing liner. The outer
encapsulation device 2700 includes cover portions 2703. Additional
impact absorbing layers can be inserted within integrated pockets
2701. Elastic band 2702 secures the impact absorbing liner to the
encapsulation device with an elastic band to tighten the complete
assembly to the wearer's head. Another elastic band 2704 is similar
to elastic band 2702, however operates as a mechanism to fasten
additional impact absorbing inserts.
[0115] FIG. 28 is an isometric view of an outer encapsulation
device 2800 similar to FIG. 27. Encapsulation device 2802
incorporates an elastic band 2801 to secure to the head of the
wearer. Pockets 2701 can be incorporated as discussed above.
Chinstrap 2803 provides an additional method of fastening the
assembly to the head of the wearer.
[0116] FIG. 29 shows an impact absorbing insert 2900 of similar
composition as outlined in FIG. 26. Insert can be fitted into a
secure pocket 2701 and held in place with an elastic band 2704.
[0117] FIG. 30 shows an exemplary profile shape for a liner which
can be infused or otherwise attached to headgear or apparel 3001.
Relief cuts 3002 are representative locations for common headgear
applications. The depth, width and length of these relief cuts can
vary to suit the shape it is intended to conform to. Profile edge
3003 is representative of one attachment implementation where
stitching can be applied to attach the liner to the headgear or
apparel.
[0118] FIG. 31 shows a base textile 3101 with additional margin
outside of the perimeter of the impact reduction insert 3102. This
additional margin can be applied to create desired seams and
stitching patterns as required for the intended design. Margin
width can be tailored during sub-assembly manufacturing to further
enhance and benefit the final headgear manufacturing process or for
alternative applications as needed.
[0119] FIG. 32 is an exemplary headgear application where drop down
member 3201 can be applied by the back of the head or skull to
provide additional surface area to secure to the users head and
provide additional coverage. Drop down member 3201 provides
increased coverage to further protect the users head when combined
with impact reduction materials. Drop down member 3201 can be an
abrupt step or smooth transition as needed for optimal fit, comfort
and aesthetics. Inner sweatband 3202 can remain at a consistent
level or be contoured to follow the line of the drop down member
3201. Stitch seam attaching the inner sweatband 3202 to the hat or
garment can be secured to the inner liner of the hat, garment or
head gear to provide a smooth exterior panel that is not
interrupted by visible stitching seams. Inside stitching seams can
also provide an internal pocket 2701 for which the impact reduction
liner can be inserted. Elastic band 3202 can be applied to further
enhance a secure fit. The intersection of the bill or brim 3203 can
be comprised of a breakaway joint or flexible hinge so that this
rigid feature does not inadvertently dislodge or misalign the
impact reduction liner from the critical areas on the user.
Exterior textile 3204 can be flexible in one or multiple directions
to allow for a secure and conforming fit for various users head
shapes and profiles.
[0120] FIG. 33 is an exemplary application for hard shell headgear
3301. Ventilation holes 3302 can be increased in size, decreased in
size, increased in quantity, decreased in quantity, remain the same
or otherwise altered to suit the desired application. The resulting
ventilation configuration can be a driving factor for the inner
impact reduction liner insert 3303. The insert can be tailored to
suit a full range of shell sizes and shapes without compromising
the performance integrity of the layered impact reduction liner.
Total number of layers of alternating foam, polymer sheeting,
textiles and the like can be adapted to specific applications and
fitment requirements.
[0121] FIG. 34 is an exemplary implementation of a liner 3401 as
used in a hard shell headgear application or apparel. Relief cuts
3402 allow for increased flexibility and conformity to the inside
of the hard shell. These relief features can also provide an
additional means of ventilation flow. Contour profile 3403 can be
applied to specific areas to allow for clearance and conformity to
the users head. One implementation of a contour can be applied over
the user's ear for additional clearance and comfort.
[0122] FIG. 35 is a view of an insert adaptation 3501 which can be
applied to the crown of a hat or hard shell headgear.
[0123] FIG. 36 is a view of an insert adaptation 3601 which can be
applied to the area of a hat or hard shell headgear that covers the
back of a user's skull.
[0124] By having separate liners 3401, 3501, 3601, the thickness
and layered material composition can be adapted to suit the
application and not compromised to be universal. An additional
benefit to having several inserts is the ability to maximize
material stock during manufacturing thereby reducing production
costs.
[0125] FIG. 37 is a view of a representative impact reduction
insert for the front panel of a typical ball cap 3703. A liner can
be secured using stitching, adhesive, pockets or otherwise fixed to
the textile of the garment. A profile edge 3701 can be adjusted to
suit various profile adaptations for any hat style and is not
limited to ball caps. The profile edge 3701 can maximize the area
covered by the impact reduction insert and offer a secure fit.
Relief cuts 3702 offer a flow path for cooling and ventilation and
provide stress relief in the impact reduction liner to allow for
folding and bending in critical locations to optimize the fit and
conformity to the users head. Relief cuts 3702 allow the impact
reduction insert to effectively contour against the shape of
various users heads. Angle, thickness, location and shape can be
adjusted to suit specific applications and is not limited to
headwear. Relief cuts 3702, can be applied to any garment or
application where conformity to a curved surface is desired. Insert
tongue 3704 offers continuous coverage for the front of the head
when applied in headwear applications. An extrusion of insert
tongue 3704 also provides a means to attach two front panels making
them one continuous piece to minimize total components in a
headwear or garment application. Integrating panels for one
continuous panel provides additional surface coverage by relocating
seams and gaps to less critical areas. Profile shape 3705 is
designed to mate to and match the profile of extrusion 3704.
Profile shape 3705 can provide maximum coverage while allowing the
installed impact reduction insert to flex and move as needed during
application and use.
[0126] FIG. 38 is a view of an impact reduction insert liner 3804
as designed for a side panel implementation for, but not limited
to, a ball cap or the like. Insert liner 3804 can be secured using
stitching, adhesive, pockets, etc., or otherwise fixed to the
textile of the garment. The profile edges, 3802 and 3803, can be
adjusted to suit various profile adaptations for any hat or garment
style and is not limited to ball caps. The profile of edge 3802 can
maximize the area covered by the impact reduction insert and offer
a secure fit. Profile edge 3803 reflects a step down feature that
can be applied to add additional material coverage and allow for a
smooth transition to the back drop down member 3201. Relief cuts
3801 and 3802 provide a flow path for cooling and ventilation and
provides stress relief in the impact reduction liner to allow for
folding and bending in critical locations to optimize the fit and
conformity to the users head. Relief cuts 3801 allow the impact
reduction insert to effectively contour against the shape of
various users heads. Angle, thickness, location and shape can be
adjusted to suit specific applications and is not limited to
headwear. Relief cut 3802 can allow folding of the hat or garment
when not in use. The pattern can be applied to any garment or
application where conformity to a curved surface is desired.
[0127] FIG. 39 is a view of a representative impact reduction
insert for the back panel of a typical ball cap 3907. The insert or
liner can be secured using stitching, adhesive, pockets or
otherwise fixed to the textile of the garment. The profile edge
3903 and 3904 can be adjusted to suit various profile adaptations
for any garment or hat style and is not limited to ball caps. The
unique profiles of edges 3903 and 3904 can maximize the area
covered by the impact reduction insert and offer a secure fit which
conforms to the user. Relief cuts 3901 offer a flow path for
cooling and ventilation and provide stress relief in the impact
reduction liner to allow for folding and bending in critical
locations to optimize the fit and conformity to the users head.
Relief cuts 3901 allow the impact reduction insert to effectively
contour against the shape of various users heads. Angle, thickness,
location and shape can be adjusted to suit specific applications
and is not limited to headwear. Relief cut pattern 3901 can be
applied to any garment or application where conformity to a curved
surface is desired. Insert tongue 3905 offers continuous coverage
for the back of the head when applied in headwear applications. An
extrusion 3905 also provides a means to attach two back panels
making them one continuous piece to minimize total components in a
headwear or garment application. Integrating panels for one
continuous panel provides additional surface coverage by relocating
seams and gaps to less critical areas. Profile shape 3906 is
configured to mate to and match the profile of extrusion 3905.
Profile relief cut 3902 allows for additional flexing when wearing
or storing or folding or otherwise changing the shape of the
garment or hat to which it is applied. FIG. 40 illustrates a ball
cap with an attached chin strap 4003. The chin strap 4003 can be
permanently affixed or removable to suit the intended use. The
assembled product application can be applied to any garment or head
gear to which the user needs assurance of a secure fit. Mounting
locations 4001 can be placed anywhere circumferentially around the
lower portion of the hat. An exemplary mounting application for the
attachment points 4001 is to secure between the outer textile and
the inner sweatband 4005. A strap can be configured with a single
path 4003 or can branch off 4002 to offer adjustments to suit user
needs and comfort. A clearance gap 4004 can be applied to allow
clearance around the user's ear. The clearance gap 4004 can be open
to the air or covered with a fabric, performance textile, impact
reduction padding or any combination thereof to provide a means of
additional coverage of the wearers ear.
[0128] FIG. 41 illustrates a clip 4101 that is secured into a hat
or garment. The dotted line 4102 represents a stitching line which
can pass through mating features on clip 4101 to allow for a secure
attachment, while an attachment includes stitching, other
mechanisms can be used, such as mechanical rivets, adhesive, hook
and loop fasteners, clasps or the like, as needed to suit overall
requirements of the product and application. Chin strap 4103 is
shown as an exemplary use and integration of the strap 4103 to a
mating clip 4101.
[0129] FIG. 42 shows an exemplary representation of a clip which
can be applied to attach a chin strap 4003 and 4103 or other
auxiliary component. The clip 4200 can be formed of any material,
such as a textile, polymer, metal or any combination thereof as
needed to suit the application requirements. Non-staining and
non-corrosive materials are intended to protect the textile and
user from contamination. Clip 4200 can be secured to a hat or
garment using mating features 4203. Loop feature 4203 can be
applied in any shape or configuration such as square, triangle,
hexagonal, octagonal, straight, angled or the like to suit the
intended application. Section 4202 can be used to secure the strap
4003 and 4103 or otherwise be used as an auxiliary attachment point
on a hat or garment.
[0130] FIG. 43 is a close up view of a clip 4200 and chin strap
4304. Chin strap 4304 can be permanently affixed to the clip 4200
or remain removable as desired to suit the application. Gap 4303
can allow for access to remove the strap 4304 for the removable
implementation. The size and profile of the gap 4303 can be tapered
to provide an area of friction to help keep the strap 4304 properly
in place when in use. Rings 4302 are an exemplary representation of
a method by which the clip 4200 can be secured or otherwise affixed
to a hat or garment.
[0131] FIG. 44 shows a close up view of a clip 4403 as integrated
with, without limitation, a ball cap. In this application, the clip
4403 is secured into a hat or garment using the existing stich seam
as applied to secure the inner liner or sweatband 4401 and the
outer textile 4402 of a hat or garment. Clip 4403 can be applied at
any distance from the bottom edge 4404 or remain hidden with no
portion of clip 4403 being visible from the outside of the hat or
garment. Bottom edge 4404 is shown during the transition from the
front brim of a ball cap to the drop down feature 3201.
[0132] FIG. 45 shows an exemplary representation of impact
reduction seam taping 4501 as applied to a garment or hat. Taping
4501 can be textile, foam, polymer or any combination thereof to
provide impact reduction attributes. Material comprising the taping
4501 can be attached using stitching, adhesive, rivets, clasps,
hook and loop fasteners or the like. Intersection 4502 represents
an exemplary application where the impact reduction taping 4501 is
affixed on the garment or hat between the inside liner or sweatband
4503 and the outer textile 4504. Layers applied to the impact
reduction taping 4501 can range in thickness between 0.1 mm to 15
mm as needed for the intended application. Material layering can
include, without limitation, impact reduction materials 2600.
[0133] FIG. 46 shows an exemplary representation of impact
reduction seam taping 4601 which can be applied on hats, garments
or the like. Taping 4601 can be textile, foam, polymer liner or any
combination thereof to provide impact reduction attributes.
Material comprising the taping 4601 can be attached using
stitching, adhesive, rivets, hook and loop fasteners or the like.
Taping thickness 4602 represents total taping material after
subsequent layers have been applied to create the impact reduction
taping 4601 and can range in thickness between 0.1 mm to 10 mm as
needed for the intended application. Material layering can comprise
of but not limited to impact reduction materials 2600.
[0134] FIG. 47 shows an exemplary profile of a one piece liner 4700
in a flat orientation. Relief cuts 4701-4703 enable the liner to
collapse when inserted into apparel or headgear and conform to the
shape of the mating surface while remaining flexible. Relief cuts
4701 and 4702 allow for minimal gaps between the edges of the liner
when collapsed and inserted into apparel or headgear. Groove cut
4703 allows for additional flexibility in an area of curvature and
provides a means for aeration and ventilation as needed. Holes 4704
allow for ventilation in designated locations and may provide a
method to decrease overall mass of the liner. Holes 4704 may be
arranged in a linear orientation or randomly scattered throughout
the liner as needed for specific applications.
[0135] FIG. 48 illustrates a component which offers an attachment
point for a flat liner 4700 and headgear 4900 and 5000. Edges 4801
may mate to a liner as a means of positioning and/or a means of
attachment. Hole cut 4802 may be applied as an attachment point to
integrate into apparel or headgear. Hole cut 4802 may vary in size
and shape as needed for the intended application and may offer an
axis for pivotal rotation of the liner 4700. Embodiment 4800 may be
rigid polymer and range in thickness from 0.005''-0.25''. Impact
reduction foam or equivalent materials may be applied to the
surface of the component to provide additional surface coverage as
needed.
[0136] FIG. 49 shows an exemplary implementation of liner 4700 and
4901 in a collapsed orientation when installed into headgear. Edges
4902 may be positioned and adjusted to provide coverage as needed
for the intended application.
[0137] FIG. 50 shows an exemplary implementation of liner 4700,
component 4800 and installation arrangement 4900. Attachment point
5003 is an exemplary location for means of mechanically joining
component 5001 to headgear 5004. Seam 5002 illustrates a location
where component 5001 and liner 4700 may be joined.
[0138] FIG. 51 shows an alternative configuration where a liner
5000 and 5101 may be positioned backwards through rotation about a
pivotal axis 5103 for access to the front of a headgear 5102. The
orientation of the liner as illustrated 5100 allows for access
behind the liner without removal or destruction of the assembled
components. Frontal access may be used for embroidery, cleaning,
maintenance or the like.
[0139] FIG. 52 further shows an exemplary view of a liner 5202,
attachment component 5203 and headgear 5201 mechanically secured
with a button 5205 and pin 5204. Pin 5204 may provide a pivotal
axis for rotation of the liner about the headgear. Pin 5204 may
pass through component 5203 and 5201 and be secured within button
5205. In one implementation the component plate 5203 may be
permanently attached to liner 5202 as to further constrain the
components when fully assembled. Pin 5204 may be replaced with a
snap or button to allow for removal of the liner in its entirety as
needed.
[0140] FIG. 53 shows an exemplary profile of the front insert of a
two piece liner 5300 in a flat orientation prior to installation
5500. Relief cuts 5301 and 5302 enable the liner to collapse when
inserted into apparel or headgear. Relief cut 5301 allows for
minimal gaps between the edges of the liner when collapsed and
inserted into apparel or headgear. Window cut 5304 allows for
additional flexibility in an area of curvature and provides a means
for aeration and ventilation as needed. Holes 5305 allow for
ventilation in designated locations and may provide a method to
decrease overall mass of the liner. Holes 5305 may be arranged in a
linear orientation or randomly scattered throughout the liner as
needed for specific applications. Edges 5306 may be aligned to the
folding seam of headgear for collapsed orientations 5900 to further
enhance folding for storage and shipping when not in use.
[0141] FIG. 54 shows an exemplary profile of the back insert of a
two piece liner 5400 in a flat orientation prior to installation
5500. Relief cuts 5401 and 5402 enable the liner to collapse when
inserted into apparel or headgear. Relief cut 5401 allows for
minimal gaps between the edges of the liner when collapsed and
inserted into apparel or headgear. Window cut 5405 allows for
additional flexibility in an area of curvature and provides a means
for aeration and ventilation as needed. Holes 5404 allow for
ventilation in designated locations and may provide a method to
decrease overall mass of the liner. Holes 5404 may be arranged in a
linear orientation or randomly scattered throughout the liner as
needed for specific applications. Edges 5403 may be aligned to the
folding seam of headgear for collapsed orientations 5900 to further
enhance folding for storage and shipping when not in use.
[0142] FIG. 55 shows and exemplary implementation of front liner
5300 and 5502 and back liner 5400 and 5501 as installed in a
representative headgear. Seam 5503 identifies a location where
front liner 5502 and back liner 5501 may be joined. Edges 5503 may
be aligned to the folding seam of headgear for collapsed
orientations 5900 to further enhance folding for storage and
shipping when not in use.
[0143] FIG. 56 is a profile view of an exemplary headgear as
configured with a two piece liner 5500. The profile as shown may
also be applied to alternative liner quantities and configurations
as needed for an application. The drop down feature 5601 further
illustrates the dropdown member 3201.
[0144] FIG. 57 is a view illustrating a representative installation
of a back liner 5400 and 5701.
[0145] FIG. 58 is a view illustrating a representative installation
of a front liner 5300 and 5801.
[0146] FIG. 59 is a view of a representative headgear in a folded
configuration. Seams 5901 may be configured to align with the edges
of a liner assembly 5503 to enhance folding. Folding may enable
increased efficiency for storage, packaging, shipping or other
applications when not in use.
[0147] FIG. 60 is an isometric view of a representative strap which
wraps around the back of a user's head 6003 on the distal end. The
proximal end may be contoured to provide clearance around the front
of a user's ears 6001. Strap may be permanently attached or
mechanical fastened at attachment point 6004. Mechanical fasteners
may be configured for permanent installation or allow for strap
removal. Mechanical fastening methods may include rivets, hooks,
loops, Velcro, adhesive, stitching or the like. Attachment point
6004 may contain a cut or recess 4303 to mate to a fixed loop 4302
as shown in representative configuration 4300. Mating feature 6002
may be rigid or elastic. In rigid form, feature 6002 may contain
snap features or male and female mating attributes to mechanically
secure the strap 6003 and allow for adjustment. In some
implementations, the mating feature 6002 may be comprised of
elastic material which may stretch to adjust and contour to a
user's head shape.
[0148] FIG. 61 illustrates an exemplary implementation of a
wraparound strap 6102 attached to a ball cap at an intersection
6101. Attachment method may be comprised of loops 4200 which may be
secured as shown in FIG. 41.
[0149] FIG. 62 further illustrates a representative attachment
configuration whereby loops 4200 and 6201 are secured to a headgear
6202 and provide an attachment point for a strap 6203 and 4003.
[0150] FIG. 63 shows embodiment 6200 in a collapsed configuration.
The configuration as shown may be applied when the functionality of
strap 6301 is not required or for storage, shipping or other
applications. In some implementations, attachment point 6302 may
enable a secure attachment mechanism for strap 6301 which provides
a pivotal axis. In other implementations, attachment point 6302 may
enable removal of strap 6301.
[0151] The one or more layers of impact absorbing material can be
encased in fabric, fused onto fabric or otherwise mated to a fabric
liner to suit any particular application and aesthetic
considerations. The fabric liner can be made from any fabric
material, and can include antibacterial components to minimize the
spreading of germs during heavy use. The fabric liner can also be
washable, mold resistant, water resistant (either inherent from the
base material or combined with a hydrophobic coating), and can
include other components, such as metallic threading for radiation
shielding, structural strength, and other features. The fabric can
be breathable and offer moisture wicking qualities to support
drying during and after use and when washed.
[0152] In some implementations, the impact absorbing liner is
configured and formed of multiple density materials fused or
otherwise connected together in a multi-ply configuration. This
configuration provides additional application flexibility. For
example, by having an outer layer (farthest from the body of a
wearer) that is dense and rigid, an inner layer can be softer, less
dense and less rigid, allowing for a more comfortable fit without
sacrificing protection. Additionally, a rigid layer can be
interposed between two or more non-rigid layers. Further still, the
rigid layer can be implemented as a series of "bones" that form a
"skeletal" structure, which is in turn surrounded or layered on top
and/or the bottom by non-rigid layers. The rigid layer can fully
cover the part with consistent thickness or have variable
thicknesses and contours as needed for specific design
requirements. The layer can be different from the other layers in
size and shape or it can be identical to the non-rigid layers as
needed for specific applications.
[0153] A thickness of the impact absorbing liner can also be varied
or variable to suit a wide range of activities and applications.
The thickness can also be varied within the same liner to provide
custom protection without compromising weight. The profile can be
adaptive and variable from one area to another area. For instance,
thinner and lighter sections can be applied where impact is
unlikely, while heavier profiles can be strategically positioned in
high impact areas for maximum impact dispersion without adding
overall weight. One example would be to protect high impact areas
of the skull, such as the temples and where the spinal cord and
skull meet.
[0154] As discussed above, the impact absorbing liner can be shaped
to maximize head coverage for high-risk areas on a wearer's body.
Accordingly, in some implementations, a profile of the impact
absorbing liner has grooves and protrusions in strategic locations
to focus in the protection where it is needed most to maximize
impact dispersion while keeping areas with low impact risk as
light-weight as possible. In still other implementations, an impact
absorbing liner can be reversible to maximize versatility and
adjust the impact resistance and/or comfort provided by the impact
absorbing liner.
[0155] The impact absorbing liner can be permanently affixed to an
item of apparel, such as integrated into fabric of the apparel,
integrated into layers of the apparel, etc., provided with an
exposed adhesive layer for user installation or can be removable
though the use of mechanical fasteners, hook and loop straps (such
as Velcro.RTM. or the like), zippers, snaps, clips, clamps, vice,
or the like. In one example, an impact absorbing liner for headgear
can be formed to use the headgear's existing sweatband as an
anchor. Still, other containment mechanisms for the impact
absorbing liner can be used. The impact absorbing liner can include
one or more connector attachment points, which allow for easy
adjustment using any of a variety of connection mechanisms, such as
Velcro, snaps, buttons, serrated bands, etc. The impact absorbing
liner is configured to be interchangeable, and therefore is highly
versatile and easy to use among various applications. The impact
absorbing liner can further include padding, which can be
permanently or transiently affixed to an inside surface (i.e., a
surface closest to a body of wearer), for more custom fitting, as
well as added protection. The impact absorbing liner can be
manufactured in various colors and textures to suit the branding
and marketing demands.
[0156] An outer encapsulation device can be implemented to form the
impact absorbing liner as described herein. Encapsulation device
offers a means to utilize the impact absorbing liner without the
need for a separate hat or headgear. Integrated pockets can be
applied to provide a method of inserting additional impact
absorbing layers as needed for a specific application. An elastic
sweatband can be applied at the base of the device to secure the
impact absorbing liner and provide an adjustable mechanism to
attach to the head of the wearer and further secure the impact
absorbing inserts. Encapsulation device can be fitted with a
chinstrap that is either permanent or removable providing an
additional method to secure the assembly to the head of a
wearer.
[0157] Integrating Padding Into Headgear:
[0158] Headgear comprised of an impact absorbing liner sewn in,
fused on, adhered to, affixed within a pocket, hook and loop
fastener or otherwise inserted or attached to the exterior textile.
In some implementations an impact absorbing liner can be applied to
custom or existing headgear applications before, during or after
initial manufacturing. One exemplary application to fasten the
liner to the headgear is by stitching or sewing around the outer
perimeter of the liner padding. Stitching can be applied directly
adjacent to the padding for a more secure fit or be left with
additional room if greater flexibility and movement is desired.
Padding can be loosely placed on the headgear prior to stitching or
can be attached using adhesive film to enhance performance and
durability of the final assembly.
[0159] Panels can be assembled prior to stitching into the required
headgear orientation by adhering fabric patterns to specifically
designed impact reduction pads. This method allows for pre assembly
to reduce the manufacturing duration of the headgear article and
provides a margin of fabric that can be easily fastened to other
textile materials.
[0160] Primary textiles can be comprised of a woven composition
that provides structural integrity for the overall shape desired to
suit the design as well as provide a stretching attribute to
further secure the article on a user's head. Another exemplary
method of securing headgear to a user's head is through an elastic
band, draw string or the like.
[0161] Headgear can be altered or tailored during design and
manufacturing to offer additional coverage for the back of the
skull, temples or other critical areas as needed for specific
applications. Additional coverage will offer increased surface area
protection which can further be secured through elastic textiles or
additional bands as needed. Extended coverage over the occipital
lobe of the wearers head can be localized or applied with a smooth
transition taper from the front brim. Additional coverage can be
curved slightly or utilize elastic bands to further secure the hat,
headgear or garment to the wearers body. Adaptations can offer
adjustment for which the user can tailor the product to suit their
needs or be configured during manufacturing.
[0162] Coverage for the impact absorbing liner can be tailored to
specific areas of a user's head to suit high risk locations or to
meet desired application requirements. Specifying intended
performance or high risk impact zones will provide a foundation to
maximize performance and maintain a balance of unnecessary
materials and weight. This process of localized coverage can be
applied using the same process and materials for a wide array of
coverage applications; therefore increasing manufacturing
efficiency while remaining adaptable for new and unique
applications.
[0163] In one exemplary implementation, a hard shell can be applied
as needed for additional protection in specific locations. The
thickness of the shell can vary to suit applications however an
anticipated range can be, but not limited to, 0.01'' thru 0.25''.
This method can be particularly useful for baseball or other
similar applications where a projectile can impact a user's
head.
[0164] Another exemplary application is through localized material
thickness and density adaptations. Implementing unique material
density, thickness and layered attributes will further enhance the
performance for specific applications while minimizing overall
weight and bulkiness of the finished product. This method can be
particularly useful for applications where the wearer is prone to
impact in a predictable area such as in skateboarding,
roller-skating, rollerblading, or other wheeled applications where
a common impact can be realized on the back of the skull. This
method can also be applicable to users with medical conditions
causing sudden balance or equilibrium disturbances resulting in
loss of control and/or falling.
[0165] Impact Dispersion Bill or Brim:
[0166] Many existing hat designs integrate a rigid or semi-rigid
bill or brim. While this is functional for its intended purpose of
blocking light it can also provide a leverage point which can
dislodge or inadvertently remove the headgear from a user's body.
When considering impact reduction applications, keeping the
headgear securely in place is a critical component.
[0167] In some implementations, the bill or brim of a headgear
article can offer impact dispersion attributes. Bill or brim can be
made from impact reduction padding, be designed with a break-away
joint, utilize a living hinge or the like.
[0168] Use of impact reduction padding for the bill or brim can
provide additional impact reduction coverage and can remain
flexible. By remaining flexible in strategic locations, the brim
can remain functional as originally intended but also offer a
feature to further secure the headgear and as to not be forced off
of a user's head in the case of an impact.
[0169] Implementation of a break-away joint can allow the headgear
to remain in the desired place on a user's head during an impact by
dislodging the bill or brim at the critical time of impact leaving
the remainder of the headgear in place as designed. Another
implementation is through the use of a living hinge. A living hinge
is defined as a joint which offers a weak joint specifically
designed to release in the case of an impact. Applying this feature
to the bill or brim of headgear can allow a reusable design which
will minimize the risk of the headgear falling off during an
impact.
[0170] Ventilation Holes:
[0171] In some implementations, holes, cuts, grooves and the like
can be applied to optimize heat transfer from the user's body and
offer a ventilation path. These features can be designed to add
aesthetic appeal as well as weight reduction.
[0172] Hard Shell Headgear:
[0173] In some implementations, the layered impact reduction
padding can be applied to the inside of a hard shell such as
applied for helmet applications. The impact reduction liner can be
fastened to the shell through stitching, adhesive, hook and loop
fasteners (such as Velcro.RTM. or the like), encased in textiles or
the like. Layered impact reduction liner can be used in place of
traditional foam to offer increased performance and implemented in
the same manner as current design. Liner can range in thickness to
suit desired performance requirements. Common adaptations will
range in thickness from, but not limited to, 2 mm thru 30 mm.
[0174] As required from the applications performance requirements
and thickness criteria, multiple layers of alternating foam,
polymer sheeting, textiles, and the like can be applied to tailor
the performance and weight to specific attributes. One or several
layers can have an extruded profile to offer additional load
distribution surface area, cooling channels, aesthetic and tactile
benefits or the like.
[0175] Flex Grooves:
[0176] In some implementations, the impact absorbing liner includes
one or more grooves, channels, indentations, or the like,
("grooves") placed or arranged in strategic locations on one or
more surfaces, i.e. the inner surface, which allow for a smoother
shaping and contouring to a body part of the wearer, and to provide
flexibility or flexure to the impact absorbing liner for better
conformance to various body shapes and sizes. The grooves also
provide a unique profile for impact dispersion by allowing room for
the material to flex, thereby absorbing additional force. The
grooves further provide a path for air circulation to enhance
breathability and reduce moisture during use.
[0177] Casing:
[0178] The impact absorbing liner can further include a casing, in
accordance with alternative implementations. The casing can
surround only the outer, inner or all around the impact absorbing
liner to suit any particular application and/or aesthetic needs.
Colors and patterns can be added and can include logos or other
branding elements as needed. The casing can be made from
puncture-proof, puncture-resistant, cut-proof, or cut-resistant
materials, such as Kevlar thread, Teflon thread, carbon fiber
threading, or the like. The casing can be interchangeable among one
or more impact absorbing liner for sanitary or aesthetic needs.
[0179] One or more reinforcement frames can be applied or located
where needed to provide specific protection for desired
applications. This provides increased protection where it is needed
for a specific activity to balance product weight, impact
reduction, acceleration reduction and rigidity for the intended
application.
[0180] Tightening System:
[0181] A tightening system such as a drawstring or cable can be
applied for a low profile fastening mechanism that is easily
adjustable to fit the user, and can be released for flat storage or
transportation. Channel tubes can be integrated into the layers of
the product or manufactured as part of the frame to provide
seamless looping for the drawstring. Integral tubes eliminate the
need for exposed or raised channels or grommets for the drawstring,
and minimize stress concentrations on the users head, body or other
specific application. Fastening and adjustment can be made using a
knob lever or static friction groove.
[0182] The tightening system can be applied for circumferential
adjustment and/or to control the height for a customized fit. A
full coverage lattice arrangement can be applied to provide full
coverage and maximum adjustability. Multiple fastening points can
enable further adjustment and customization for the user.
[0183] The fastening device can also be operated by pinching a
latched assembly. A serrated insert can slide freely when the
latched assembly is pinched open, and lock when released. Allen
wrenches or other tools can be used either in conjunction with the
pinch-activated fastening device, or independently. The fastening
device can also include a rotating knob to wind a tightening cord,
and can be applied either to the liner or as part of the frame. The
rotating knob includes a disk that is turned by hand and has a low
profile. Allen wrenches or other tools can be used either in
conjunction with the knob system, or independently.
[0184] Adjustment is provided in circumferential and/or vertical
planes or directions, for universal fit for all head shapes and
sizes. Accordingly, the impact absorbing liner can be easily
adapted to varying sizes of body parts, such as varied head
roundness, width, length or other dimension. The flexibility of the
material can provide further for fine adjustment and a snug, secure
fit.
[0185] Alignment Holes:
[0186] Holes can be placed in strategic locations for aiding
assembly by providing alignment guides. In some implementations,
the alignment holes can be unique or universal to utilize the
existing aeration holes (as previously described). A size of the
holes can be customized to adapt to existing manufacturing jigs,
and the holes can be located for additional attachment points. The
alignment holes can also be strategically located throughout the
part to allow stress relieve over a contoured area of the body or
equipment being protected. This can minimize bunching and increase
the overall surface area coverage on complex and contoured
areas.
[0187] Folding Parts:
[0188] By folding each component within the part, the total number
of parts within the assembly are reduced. Creases and outside
profiles are configured to enable flat packaging and folding for
storage when product is not in use. This profile can conform to the
inside of the user's headgear, outside of the head or other
configurations as needed for the application.
[0189] The shape and profile of the impact absorbing liner provides
maximum coverage when worn or applied on the users body (via
headgear or apparel) while allowing for a universal fit that is
adjustable for adult and youth sizes. The versatile design ensures
full coverage for strategic locations. Thickness and density of
protective layers are provided and can be varied in specific
locations to support performance objectives for intended
applications.
[0190] In some implementations, the profile, material thickness and
densities employed in the impact absorbing liner are adaptable to
fit within the sweatband of existing or custom headgear as to not
require a larger or replacement hat, garment or other covering to
properly use. Arcs on the "wing" sections of the part provide
increased surface coverage when folded into the headgear or garment
and in general for highly contoured surfaces.
[0191] Strategic cuts can be placed in the part to encourage
conformity when applied to curved surfaces. In one example, the
headgear liner has cuts on the wing sections to conform the users
head shape. This conformity can provide additional and complete
coverage compared to not having relief cuts. Relief cuts placed at
areas of curvature to enable conformity to the mating surface.
[0192] Adhesive Layers:
[0193] One or more wet or tacky adhesive layers can be applied to
attach several layers of varied thicknesses and densities. In some
implementations, a dry adhesive can be heat sensitive which can
allow for easier final alignment before "setting" in position. An
adhesive can be installed via sheet/spray/film/etc. is applied
before or after profile cutting.
[0194] Adhesion for each layer can occur before part cutting to
simplify assembly. Where required, adhesive is applied after part
cut out or before cut out. If assembly of the parts is required
after cut out, a release liner is applied to the adhesive layer to
allow for proper alignment and storage prior to final assembly.
[0195] Snap-Back Clasp:
[0196] A clasp can be integral or provided separately to fasten the
liner to the existing clasp on snap-back hats. The clasp on the
product can be low profile as to be universal for multiple hat
applications and not limited to snap-back hats. The clasp maintains
alignment and provides a mechanism to fasten the liner within the
headgear or hat.
[0197] The clasp can be mechanically attached to the liner using
adhesive, rivets, clamps, sewing, hook and loop attachments (i.e.
Velcro), or the like. Additionally, the clasp can be permanently
vulcanized to the foam or inner frame.
[0198] Temple and Spinal Guard:
[0199] The impact absorbing liner can be positioned below the hat
line to offer additional coverage over the temple. Applications
include, but not limited to, baseball base coaches, sporting
coaches, baseball pitchers, baseball catchers, golf or any activity
where a projectile could contact a user's temple. A temple guard
can be applied on either the left or right side, and can be formed
of the multiple layer technology described herein. One or more
additional outer shells can be applied to provide additional
protection. If an outside shell is used, it can provide a
foundation to contour the guard to match the users head profile for
a custom or form fitted part. An area of the user's body where the
skull and spinal cord meet can have a multi layered protective
protrusion to protect against a direct impact to the back of the
head.
[0200] Layered Material:
[0201] In some implementations, an article of manufacture includes
a layer of impact absorbing material followed by a rigid or
semi-rigid layer, followed again by another layer of impact
absorbing material. Additional layers of similar composition can be
added and affixed to the assembly as needed to achieve the desired
thickness and impact reduction performance.
[0202] The impact absorbing material can be made of "smart
molecules" that harden on impact, open cell urethane foam rubber,
closed cell urethane foam rubber, silicone elastomer,
polycarbonate, Kevlar, textiles or the like, and formed to fit the
unique profile needed for a specific application.
[0203] The material can be provided in sheets of varying length and
width dimensions, rolls of varying widths, patterns or the like as
needed for a specific application. Material can be manufactured
with or without fabric, with or without adhesive exposed for
attaching to substrate, equipment or coverings or the like.
[0204] Each layers thickness can be custom tailored for specific
applications. The Impact reduction material thickness can range
from 0.5 mm to 15 mm and density can range from 5 lb/ft 3 to 50
lb/ft 3. The denser layer can be placed on the side of the impact
but can also be aligned on the inside liner which contacts the
protected surface. The less dense layer can be placed on the side
of the protected surface but can also be arranged on the side of
impact. Multiple layers of impact reduction mater and rigid
substrate can be applied in various sequences to suit the specific
application. A dense layer of impact reduction material can be
placed directly onto a less dense layer of impact reduction
material creating a unique performance characteristic. Rigid liner
substrate can be applied in multiple locations as needed for the
application.
[0205] Individual Insert:
[0206] In some implementations, an article of manufacture includes
a contoured hard outer shell and layered impact absorbent liner
inside. The impact absorbent liner can have an integrated
intermediate frame, formed of different materials or densities, the
same material or densities, or any combination thereof. A contoured
shell can be flexible or pre-formed to match the contour of the
mating surface. In one exemplary application for headgear, the hard
shell can be shaped to fit the inside of a hat or the contour of
the head. A shape of the impact absorbing liner can vary to suit a
desired application. Each application can consist of several
individual shapes of the same or different dimensions as needed to
suit the application.
[0207] The individual inserts can be attached to an existing
garment or structure as to not be visible from the outside.
Individual inserts can be applied independently or in a sequence as
to provide partial or full coverage as needed for the application.
An attachment mechanism can be permanent or removable as needed for
the application. Attachment mechanisms can include, but not limited
to, wet adhesive, dry adhesive, rivet, snap, button, zipper, hook
and loop fastener, interlaced string, sewn, vulcanization, or the
like.
[0208] Rotating Assembly
[0209] In some implementations, the embodiment can be secured using
a mechanical fastener such as a rivet, pin, rod, button or the like
to hold components together while allowing free rotation about a
pivotal axis. Total rotation can be free of any restriction or
confined to a angular constraint as needed for a specific
application. In one exemplary application, the rotation of a liner
may allow for access to the inner portion of a headgear that would
otherwise be covered by a liner. This access may allow for
embroidery, repair, cleaning, maintenance or other customizations
as needed. The embodiment may be rotated or configured back to the
original orientation as many times as needed over the life of the
component. The embodiment can be further constrained using
mechanical fasteners such as Velcro, snaps, buttons, stitching,
adhesive or the like as to prevent unintended rotation during
storage, shipping or active use.
[0210] Securing Strap:
[0211] A securing strap may be applied as an additional method of
securing headgear to a user's head. The securing strap can be
permanently integrated into the liner or headgear or be removable.
Either configuration may utilize mechanical fasteners such as
rivets, Velcro, hooks, loops, snaps, buttons, or the like. Straps
may be fixed length or be adjustable. Methods for adjustability may
include elastic bands, elastic fabric, snap features, buttons,
clasps, or the like. The securing strap may be configured to wrap
around a user's chin or around the back of the head. For the back
of the head configuration, the strap may be sized and positioned as
to rest just below the occipital lobe or on the back of the head.
The straps may be configured to allow for easy removal or may be
positioned out of the way while not in use. In some implementations
when a strap is positioned out of the way it may remain attached to
the headgear.
[0212] Miscellaneous:
[0213] The impact absorbing liner can include a loop applied to the
side, front or rear edge of the assembly to allow for attachment to
a belt or bag when not in use. The loop can be attached using a
mating hook, loop or carabineer. The loop can be integral to the
internal structure or attached to the final assembly using
adhesives, button, snap, clamp or sewn in.
[0214] Automatic adjustment can be achieved using a slide-lock,
rotational-lock, or other interval locking device. The interval
locking device is designed so that adjustment is easily achieved
while in use but does not have adverse protective or aesthetic
affects from protrusions, which can cause a point load and risk
injuring the user on impact. Adjustment can also be achieved using
a removable tool.
[0215] A gripping material can be applied to either the inside or
outside of the impact absorbing liner as needed to ensure a secure
fit on the user's head or piece of equipment during extreme use.
The gripping material can be integral with the liner manufacturing
or added on as a post manufacturing feature. The gripping material
can be a firm elastomer which is formulated to provide maximum
adherence especially during active, cold, hot, wet, dry, dusty and
other environments.
[0216] The impact absorbing liner can also include one or more of
reflectors, lights and glow-in-the-dark or other luminescent
materials ("light features"), which can be applied for
customizations and for safety during low light use conditions. The
light features can be arranged to enhance branding, logos, or
otherwise custom graphics as needed or desired, and/or applied in
zone-based locations to enhance visibility during a particular
sport or activity.
[0217] The impact absorbing liner can further include one or more
accessory mounts for electronic devices, phones, cameras,
computers, data collection devices, storage devices, sensors,
Global Positioning System (GPS), headphone attachments, speakers,
or the like.
[0218] Electronic Adaptations:
[0219] The impact absorbing liner can include a radio frequency
(RF) protection liner that can be applied as a coating or physical
liner. The RF protection liner can be integral with the impact
absorbing liner, provided as a casing or as a separate add-on
product. RF protection liner can be affixed using the structural
frame for a secure fit.
[0220] In some implementations, the impact absorbing liner can
include one or more sensors can be connected with or integral with
any part of the impact absorbing liner, to measure and record
G-forces, forces of impact, speed, elevation changes,
geo-positioning or location data, impact data, biometric data such
as heart rate, body temperature, breathing rate, calorie
consumption, calories burned, or the like. The sensors can be
configured to communicate wirelessly or via wired connection to a
smartphone or computer device for monitoring by medical staff or
spectators while worn by the user. A data connector, such as a
universal serial bus (USB) connector, can be adapted to download
recorded data.
[0221] Lighting can be integrated into the liner by layering within
the material during manufacturing, incorporating into the internal
frame or the like. Lighting can be light emitting diode (LED),
liquid crystal display (LCD), or any other light emitting
mechanism. The lighting can be powered by external batteries,
rechargeable power source, solar panels or the like. The lighting
can be placed in any direction as needed for the application.
Placement can be, but not limited to, head lamp, side indicators,
back indicators or the like. Applications include but not limited
to hiking, biking, walking, running, jogging, sports, hobby
projects, camping, baseball, football, hockey, skateboarding,
reading, or the like.
[0222] A wireless communication connectivity such as Bluetooth or
other can be provided for head phone or cell phone connectivity,
and for controls for media devices for hands free convenience.
Wireless communication can also be used to communicate biometric
data from the impact resistant liner to a mobile device or storage
device.
[0223] A self-correcting mechanisms can be integrated to enable
automatic resizing and automatic placement for ease of use and
interchangeability. Solar panels can be applied to power integrated
sensors or for external devices such as phones, watches and
computers. Headphones, hearing aids and microphones can also be
integrated as an add-on or integrated into the apparel design for
specified user communities and applications.
[0224] Although a few embodiments have been described in detail
above, other modifications are possible. Other embodiments may be
within the scope of the following claims.
* * * * *