HK1248479A1 - Protective headgear for sports participants, especially baseball fielders - Google Patents

Description

Protective headgear for sports participants, in particular baseball fielders

Cross Reference to Related Applications

This application is based on and claims priority from U.S. provisional patent application 62/134,337, 2015, 3-month 17-day, and U.S. provisional patent application 62/294,444, 2016, 2-month 12-day, each of which is incorporated by reference in its entirety as if set forth explicitly herein in its respective entirety.

Technical Field

The present invention relates to sports equipment and, more particularly, to protective headgear designed to be worn by baseball or softball fielders, particularly pitchers, to protect the fielder's head and face from being struck by a struck ball.

Background

Baseball is well known as one of the entertainment activities of americans. Baseball is a "bat + ball" type sport that competes between two teams of nine players, each player taking turns to hit a ball and defend. An aggressor attempts to score a score by hitting a ball thrown by a pitcher with a bat and moving counterclockwise around a series of four bases (i.e., first base, second base, third base, and home base). One point is scored as the player progresses around each base and returns to home.

The fielder wears gloves to assist in holding a shot and typically wears a soft hat as part of their uniform. The hit balls reach high speed and it is therefore desirable to protect the head and face of the fielder from the hit balls.

Disclosure of Invention

In one embodiment of the invention, a protective headwear for a baseball or softball fielder (e.g., pitcher thereof) is provided and includes a rigid outer protective shell having a front, a first side, an opposing second side, and a rim extending outwardly from the front. The outer protective shell has a top opening and a rear opening defined between a first free end of the first side and a second free end of the second side. As a result, the protective headgear does not completely surround the head of the wild hand. As described herein, the top opening allows the head to be more easily "ventilated" (allowing air and moisture transfer), while the rear opening allows the size (circumference) of the outer protective shell to be modifiable to ensure a proper snug fit regardless of the size of the wild head.

The protective headgear also includes an impact absorbing material disposed along an inner surface of the outer protective shell, and also includes an inner cap to be worn beneath the outer protective shell. In at least a portion of this embodiment, the headgear includes an impact-absorbing region formed as a multi-layered structure formed from two or more energy-absorbing materials. The inner cap is formed of a breathable material and may be in the form of a rimless cap.

Drawings

FIG. 1 is a front and side perspective view of a protective headgear according to another embodiment of the present invention;

FIG. 2 is a rear and side perspective view of the protective headgear of FIG. 1;

FIG. 3 is a top plan view of the protective headgear of FIG. 1;

FIG. 4 is a bottom plan view of the protective headgear of FIG. 1;

FIG. 5 is a front view of the protective headgear of FIG. 1;

FIG. 6 is a front view of the protective headgear of FIG. 1 in use;

FIG. 7 is a front view of the protective headgear of FIG. 1 with an optional eye shield (ocular shield);

FIG. 8 is a right side view of the protective headgear of FIG. 1 with an optional eyeshield panel;

FIG. 9 is a front perspective view of an eye shield plate for use with protective headgear;

FIG. 10 is a front perspective view of an inner cover for use with the protective headgear;

FIG. 11 is a right side view of the protective headgear of FIG. 1 in use;

FIG. 12 is a left side view of the protective headgear of FIG. 1 in use;

FIG. 13 is a rear view of a ratchet mechanism for tightening the helmet;

fig. 14A shows an impact absorbing layer according to a first embodiment; and

fig. 14B shows an impact absorbing layer according to a second embodiment.

Detailed Description

Fig. 1-13 illustrate a protective headgear 100 for use by an athletic participant, more specifically, the protective headgear 100 is specifically configured for use by a participant in athletic activities, and more specifically, by a baseball fielder such as a baseball pitcher. Protective headgear 100 can also be considered a protective helmet or hat. As described herein, the protective headgear 100 includes features for protecting the head and face of a player from being struck by a struck ball.

The protective headgear 100 includes a plurality of different components that are assembled to form a complete product, and more particularly, the protective headgear 100 includes an outer protective shell 110. The outer protective shell 110 does not completely enclose the head of the user (athlete), but is instead designed such that it has an open top and an open back. More specifically, the outer protective shell 110 has a front 120, a first side 130, an opposing second side 140, and a rim 150 extending outwardly from the front 120. The outer protective shell 110 has a top opening 160 and a rear opening 170 defined between the free end 132 of the first side 130 and the free end 142 of the second side 140.

From a top perspective, the outer protective shell 110 is generally U-shaped, wherein it has an open rear as described above (i.e., the legs of the U are not continuous with each other). The U-shape allows for bending to accommodate different head sizes and thus serves as a mechanism to ensure proper fit to the user (wild hand). The outer protective shell 110 has a top edge 111, the top edge 111 defining a top opening 160 and extending across the front 120 from the free end 132 of the first side 130 to the free end 142 of the second side 140. The top edge 111 is also U-shaped. The bottom edge 113 of the outer protective shell 110 is defined by and extends across the first side 130, the edge 150, and the second side 140.

As shown in the views of fig. 1 and 5, the top edge 111 in the front portion 120 may be slightly raised relative to the top edges 111 of the first and second sides 130, 140.

First side 130 can be considered a left side ear cup and second side 140 can be considered a right side ear cup. When protective headgear 100 is intended to be used by a baseball pitcher, as shown and described herein, one of first side 130 and second side 140 may provide additional protection in terms of the pitcher's normal mechanics and motions when the ball is released.

It should also be understood that in one embodiment, the first portion 130 and the second portion 140 may both be modular and may be configured to allow the first portion 130 and the second portion 140 to be selected for certain parameters, such as physical characteristics of a user (wild hand). In this embodiment, the portions 130, 140 may thus be detachably coupled with the main (base) portion of the headgear. For example, a mechanical fit, such as a releasable snap fit, may be provided between the portions 130, 140 and the main (base) portion to allow a user to select one portion 130 from the set of portions 130 and one portion 140 from the second portion 140. In addition, other components (including the rear tensioning mechanism for the tightening headgear) may also be configured to be modular in nature. Various types of exemplary rear tensioning mechanisms are described herein.

Typically, the hand is swung and starts throwing when his arm is closed in front of the body, which is called a preparation set. After preparation, the pitcher takes one step toward home base and throws. Typically, the pitcher uses a high kicking leg from preparation, stepping toward home base when pitching; the pitcher could instead release the ball faster by using a sliding step, taking a step directly and immediately toward home base and throwing. After the ball is released, the pitcher occupies the defensive position. The natural body movement of the pitcher exposes one side of the head more than the other based on whether the pitcher is a left-handed pitcher or a right-handed pitcher. More specifically, if the pitcher is a right-handed pitcher, the right side of the head is more exposed to the strike of the ball, and similarly, if the pitcher is a left-handed pitcher, the left side of the head is more exposed.

As described below, fig. 1 to 13 show protective headgear that has an increased protection due to the fact that the temple protection can be asymmetric, wherein the temple protection on the dominant side of the player (temple protection) is increased, thereby resulting in a different temple protection structure. In another embodiment (not shown), the left portion 130 and the right portion 140 may be mirror images of each other, since the protective headgear of this embodiment provides symmetrical temple protection (temple protection) and over-the-ear coverage.

More specifically, for purposes of illustration only, fig. 1-8, 11 and 12 show a protective headgear 100 for a right-handed pitcher having enhanced temple protection on the right side (the pitch side in this example); however, it should be understood that in the protective headgear 100 for a left-handed pitcher, the additional protection is merely the reverse and is part of the left side portion 130.

For a right-hand pitcher, the left (first side) portion 130 does not cover the athlete's left ear, but instead exposes the left ear as shown in fig. 6. The left side portion 130 includes a first section 134 that provides temple protection and is seated on the head immediately anterior to the left ear. The bottom edge of the left side portion 130 has a sharply curved section 136 that receives the left ear and is disposed above the left ear during wear of the protective headgear 100. The curved section 136 tapers down to the free end 132 of the left portion 130 in the posterior direction of the left ear.

As described above, for a right-hand pitcher, the right side (second side) portion 140 includes enhanced protection, wherein the right side portion 140 overhangs below and substantially covers the right ear as shown in fig. 6. An ear vent (opening) 141 is formed in the right side portion 140 to allow air to reach the ear. As with the left portion 130, the right portion 140 has a first section 144 that covers the temple and sits on the head immediately in front of the right ear. The right side portion 140 extends over and covers the area of the head immediately behind the ears. Right side portion 140 may include a second section 145 located below ear vent 141.

As shown in the figures, the right side portion 140 may be configured such that it also extends across the upper portion of the chin. The illustrated ear vent 141 has a generally triangular or elongated shape and extends forwardly toward the face. However, it should be understood that ear vent 141 can have many other shapes and can also have different sizes.

The left portion 130 may be considered a left wing extending rearward, while the right portion 140 may be considered a right wing extending rearward and disposed to span from the left portion 130. As described herein, the left wing 130 and the right wing 140 are flexible in nature to allow the protective shell 110 to mate with different sized heads and to allow the protective headgear 100 to be closed and opened. In other words, the flexibility of the wings 130, 140 allows the two structures to be drawn toward each other to tighten the headgear 100, or they can be further spread apart to loosen the headgear 100.

The outer protective shell 110 may be formed as a single piece (part) using conventional manufacturing techniques such as a molding process. The outer protective shell 110 may be formed from a number of rigid materials suitable for use in the present application. In one exemplary embodiment, the outer protective shell 110 is formed of a composite material, and more specifically, the outer protective shell 110 is formed of a carbon fiber/aramid composite material for the purpose of distributing impact energy across a range greater than the initial impact position. For example, the outer protective shell 110 may be made of a carbon fiber/aramid composite material having a thickness between about 1mm and about 5 mm.

In one exemplary embodiment, the outer protective shell is formed from three layers of carbon fiber. For example, a triple layer carbon woven cloth is combined with (embedded in) an epoxy resin to form the shell. The three layers may be placed in an aluminum mold, clamped against each other with internal removable silicon "plugs", and then dried together so that the epoxy flows through the three layers of carbon fiber fabric. Once it cools, the epoxy hardens and the three-layer carbon fiber fabric acts as a vibration barrier distributing impact energy.

As described herein, the outer protective shell 110 may have a variable thickness (e.g., between 1.0mm and 1.5 mm). The two impact zones are formed with a thickness of 1.5mm, while the rest of the shell is formed with a thickness of 1.0 mm. Two impact zones 1.5mm thick are defined as the "front" and "side" impact zones as described herein and as defined in the NOSCAE test protocol. The increased local thickness allows the headgear 100 to pass testing in both impact zones, while the remainder of the shell 110 is thinner (1.0mm) to keep weight to a minimum.

It should be understood that other materials may be used to form the outer protective shell 110, and in particular, the shell 110 may be formed as a non-composite structure. In some applications, the shell 110 may be formed of polycarbonate or other suitable material. The shell 110 may also be constructed such that it includes a honeycomb (honeycomb) or bonded (bonded) sandwich of copolymer extruded materials. In addition, the shell 110 may be configured to include a foam substructure of insert molded EPS foam chemically bonded (or otherwise bonded) to the outer shell 110.

The protective headgear 100 includes an impact absorbing structure (material) 200 disposed along and secured to the inner surface of the outer protective shell 110. The impact absorbing structure (material) 200 may be formed as a single layer from a single material, or may be formed from two or more layers formed from different materials as shown in the exemplary drawings. The impact absorbing structure 200 is intended to provide primary impact absorption. The structures (materials) forming the headgear provide a level of impact absorption; however, the primary area of impact absorption is structure 200. The bond between the shell 110 and the structure 200 (e.g., a honeycomb structure as described herein) may have high strength to help engage the material of the structure 200 upon impact (e.g., a cell structure that helps engage the honeycomb material upon impact).

In the illustrated embodiment, the impact absorbing structure 200 is formed of two layers of material that provide the desired impact absorbing properties. For illustration purposes only, the figures show solid blocks of the impact absorbing structure 200 without distinguishing the two layers that make up the structure 200. Exemplary materials for forming the two-layer structure 200 are shown in fig. 14A and 14B. For example, impact-absorbing structure 200 is formed from a first layer 210 and a second layer 220. The first layer 210 is disposed against the inner surface of the outer protective shell 110, and the second layer 220 is disposed against the first layer 210. The coverage (footprints) of the first layer 210 and the second layer 220 may be the same or may be slightly different. Typically, the coverage of the first layer 210 and the second layer 220 will be at least substantially the same.

For example, the first impact absorbing layer 210 may be formed of a thermoplastic honeycomb formed of a co-extruded Polycarbonate (PC) containing for energy absorption. The structure provides uniform mechanical properties due to its circular cell structure and provides high compressive strength in low density materials, thereby reducing transmitted forces and peak g-force acceleration. Honeycombs are highly efficient energy absorbers, which are critical for impact protection and are highly breathable. Depending on the cell size and the polymer density compressive strength (DIN53421), the material has been tested and this test has demonstrated a durability of 101 to 522psi (0.7 to 3.6MPa) with compressive strength increasing as the cell size decreases. The inter-cell connection is achieved without the use of adhesive glues but by thermal welding which improves visual and performance consistency. The individual tubes are coextruded to have an inner layer and an outer layer, each layer comprising a different polymer; the outer layer has a lower melting point than the inner layer. The tubes are stacked in a mold, which is then heated and pressurized to melt the outer layer of each tube, thereby providing a heat weld between all adjacent tubes. The tube is then cross-cut into sheets (sheets). The welded honeycomb panels may be further processed by milling, thermoforming, cutting, profiling, laminating, plating, etc. to final size and shape parts.

In one exemplary embodiment, the first impact absorbing layer 210 may have a thickness between about 3mm to about 15mm (e.g., 10mm thick). The coverage of the first impact absorbing layer 210 may be the same as or similar to that of the outer shield shell 110. A number of means may be used to attach the first impact absorbing layer 210 to the inner surface of the outer protective shell 110. For example, an adhesive or other bonding agent (e.g., a pressure sensitive adhesive) or mechanical fastener may be used to attach the first impact absorbing layer 210 to the inner surface of the outer protective shell 110. Exemplary attachment means also include RF welding, thermal bonding (e.g., heat activated epoxy film adhesive, etc.).

In another embodiment, the first impact absorbing layer 210 may be an impact absorbing material provided in the form of a flexible layer of plastic cushioning material that may provide a nearly linear force-displacement curve (force-deflection curve) that allows for maximum comfort throughout the compression and impact cycles. The layer of flexible plastic cushioning material may be formed from a plurality of molded flexible polymeric resin components that include inwardly directed indentations. The first layer 210 may have a thickness of about 13 mm. It is understood that the first layer 210 may be formed to have other thicknesses; however, the first layer 210 will typically have a greater thickness than the second layer 220. The first layer 210 is shown in fig. 14A.

The second layer 220 may be in the form of a protective pad product, which may be in the form of a polyurethane foam formed using breathable, antimicrobial, open cell or closed cell technology to provide impact protection and comfort. The second tier 220 is shown in fig. 14B. The second layer 220 may have a thickness between about 2mm and about 9 mm. It is understood that the second layer 220 may be formed to have other thicknesses; however, the second layer 220 will typically have a greater thickness than the first layer 210. It will also be appreciated that the innermost layer of the impact absorbing material may have moisture wicking properties which are advantageous as the innermost layer is in contact with the hair and head of the user. For example, the innermost layer may be encapsulated (packaged) with a moisture wicking antimicrobial fabric or the like, or a thin layer of moisture wicking material may be applied to the inner surface of the innermost absorbent material.

As shown in the drawings, the impact absorbing structure 200 may cover most of the inner surface of the outer shield shell 110; however, layer 200 (for a right-hand pitcher) may be eliminated from a portion of right-hand portion 140. More specifically, the second section 145 of the right side portion 140 that covers and overhangs the ear may be devoid of the impact absorbing structure 200. The outer protective shell 110 still covers these areas and thus provides protection. The absence of the structure 200 allows sound to travel directly to the ear without significant attenuation from surrounding structures.

Fig. 1-8, 11 and 12 illustrate a protective headgear 100 incorporating a two-layer impact-absorbing structure 200 described herein; however, a single layer of absorbent material may equally be used or structures having more than two layers may equally be used, provided that the structures are capable of performing the intended function (i.e. absorbing the applied force).

The protective headgear 100 includes a mechanism for adjusting the protective headgear 100 so that a secure fit is formed on the head of the user. Fig. 13 shows a mechanism 300. The mechanism 300 is located behind the protective headgear 100 and can be easily adjusted by the wearer of the protective headgear 100 to provide a safe, customized fit at a time. By manipulating the mechanism 300, the left side portion 130 and the right side portion 140 may be drawn together to tighten the headgear 100 around the head of the wearer. Conversely, if the mechanism 300 is manipulated in the opposite manner, the left side portion 130 and the right side portion 140 separate from each other, thereby loosening the headgear 100 around the wearer's head. The mechanism can thus be operated by one hand.

In the illustrated embodiment of fig. 13, the mechanism 300 is in the form of an adjustable ratchet closure system having a first end 302 attached to the left side portion 130 and a second end 304 attached to the right side portion 140. One or more actuators 310 of the mechanism 300 are configured to draw the ends 302, 304 together or cause separation between the ends 302, 304 and relaxation of the protective headgear 100.

The present figures illustrate different types of adjustment mechanisms that may be used, including some that utilize a ratchet mechanism or the like to draw the side portions 130, 140 together. For example, fig. 1-8, 11, and 12 illustrate an alternative mechanism 301 for adjusting the protective headgear 100 such that a secure fit is formed on the head of the user. The structure 301 may be a ratchet-based system or another type and operated by the wearer manipulating an actuator (e.g., a knob) to cause tightening or loosening of the structure 301 by drawing the sides 130, 140 together.

As shown in fig. 4, the mechanism 301 may be connected to the side portions 130, 140 by elongated elastic bands 303, 305, respectively. These straps 303, 305 allow the mechanism 301 to move as the headgear is placed on or removed from the head and during wear.

Alternatively, an elastic tension band (not shown) may be provided between the side portions 130, 140. In yet another embodiment, the mechanism 300 may be of the interchangeable type, wherein the free ends of the side portions 130, 140 may include connectors or the like for releasable connection with the mechanism 300 to allow the wearer to choose to replace one mechanism with another. For example, a ratchet mechanism having a complementary connector at its end may mate with a connector at the free end of the side portions 130, 140, and similarly, an elastic tension band having a connector at its end may mate with a connector at the free end of the side portions 130, 140. This allows customization of the mechanism 300 for tightening the headgear 100.

Additional adjustment mechanisms may also be used with headgear 100.

Protective headgear 100 is preferably intended to be worn with inner cap 500 (fig. 10). The inner cap 500 is formed of a breathable material and is configured to not interfere with the use of the protective headgear 100. For example, the inner cap 500 may be in the form of a rimless cap formed from a breathable mesh. As is known, rimless caps are stretchable to provide a tight fit when worn on the head. As a result, protective headgear 100 can be easily worn on rimless hat 500. Since the protective headgear 100 is open along its top, the top of the rimless cap 500 is visible when the cap and headgear 100 are combined. It should be understood that the rimless cap 500 may be formed to have one color and the protective headgear 100 may be formed to have another color. Indicia such as team insignia may be provided on one or both of the rimless cap 500 and the protective shell 110.

Since the inner cap (rimless cap) 500 is a separate component, it can be easily removed and cleaned or otherwise disposed of. This flexibility also allows for slight changes in the appearance of the headgear, wherein the color and/or indicia on the inner cap can be changed by simply replacing the inner cap.

In one embodiment, inner cap 500 and protective headgear 100 can be configured such that inner cap 500 is fixedly yet releasably attached (coupled) to protective headgear 100. In particular, the inner cap 500 may be attached to the protective shell 110 or even the impact absorbing structure 200. Many different fastening techniques may be used to attach the inner cap 500 to the protective headgear 100. For example, one or more fasteners (e.g., buttons, hook and loop material, etc.) may be used to attach the inner cap 500 to the protective headgear 100. One half of the fastener pair is associated with the inner cap 500, while the other half of the fastener pair is associated with the headgear 100 (e.g., the protective shell 110 or the impact absorbing structure 200).

In another embodiment, a bead may be formed along the perimeter of the inner cap 500 and may be received within a corresponding groove formed in the protective headgear 100 (e.g., the groove may be formed in the shell 110 or the impact absorbing structure 200). To attach the inner cap 500 to the protective headgear 100, a sealing strip is inserted into the channel. To release the inner cap 500, the sealing strip is removed from the groove.

The attachment of the inner cap 500 is not permanent as it is directed to periodically removing the inner cap 500 for cleaning thereof.

It should also be understood that the headwear disclosed herein may be customized for a particular person using software that allows the user to take measurements prior to manufacture. For example, 3D head scanning techniques may be used to ensure optimal player fit, wherein such collected data (measurements) may be taken into account to form the shape and size of various components of the headwear.

The protective headgear 100 may include a number of optional accessories. Fig. 7 to 9 show the eyecup plate 400. The eye shield 400 can have many different shapes and sizes. For example, the eye shield 400 may have a half shield form as shown in the above figures or may have a full shield form (not shown) or other dimensions. In the illustrated half mask form, the mask 400 covers the eyes and the bottom edge extends across the nose. The eye plate 400 is formed of a material suitable for use with optical elements and is therefore formed of an optical grade material. For example, in one embodiment, the eye shield plate 400 may be formed of high strength polycarbonate and may have a thickness of about 2mm to about 3 mm.

The eye plate 400 has an arcuate (curved) shape that terminates in a first end 402 and an opposite second end 404. The first end 402 is attached to the first (left) side 130 and the second end 404 is attached to the second (right) side 140. Many different techniques may be used to couple and securely attach the ends 402, 404 to the respective first and second sides 130, 140. For example, the attachment may be of a detachable type or may be permanent in nature. To attach the ends 402, 404, fasteners 410 or the like may be used. Additionally, a mechanical coupling may be used to attach the eyecup plate 400 to the outer protective shell. For example, one of the outer protective shell 110 and the ocular shield 400 may include a protrusion, while the other of the outer protective shell 110 and the ocular shield 400 may include a slot that receives the protrusion. The groove may include a locking portion into which the protrusion slides to thereby lock and attach the eye patch panel 400 to the case 110.

Additionally, as shown in fig. 9, the ocular shield 400 may also include an upper lip (top lip) or flange 415 that includes an opening 412 that may mate with a complementary feature (e.g., a locking tab) that is part of the protective shell 110, for example, along the underside of the rim. This provides additional attachment points between the eye shield 400 and the protective shell 110 in addition to the attachment on the sides (temple portions) 130, 140 of the protective headgear 100.

In one embodiment, protective headgear 100 includes an outer protective shell 110 and an impact absorbing structure 200 that may be in the form of a multi-layer structure as described herein.

As described above, the outer protective shell 110 may have a variable wall thickness, more specifically, the shell structure is optimized to provide additional protection where the wearer is most vulnerable and thinner in other less vulnerable areas to minimize weight. In particular, the areas of increased likelihood of injury are the forehead, temple area and both sides of the head. In fig. 1-8, the area of increased thickness, indicated at 612, is apparent and visually appears as a slight bulge along the shell surface. The transition from one region 612 of increased thickness to an adjacent region or area of reduced thickness, identified at 614, is marked with an inclined surface 615. The sloped surface 615 coordinates the two regions 612, 614 together in an aesthetically pleasing manner. The areas of increased thickness 612 may be located on both sides of the outer protective shell 110, or may be located on only the side that includes the ear protection and marks the side that faces the direction of the ball throw (the pitcher's mound).

By varying the thickness of the outer protective shell 110 in a localized manner, the shell 110 provides increased protection in vulnerable areas, while non-vulnerable areas have a reduced thickness, which provides a reduction in the overall weight of the protective headgear 600.

The outer protective shell 110 may be formed of the same material as the outer protective shell 110, and thus may be formed of a composite material as discussed herein.

As discussed herein, impact absorbing mechanism 200 may be formed from a first layer 210 and a second layer 220. The first layer 210 is adjacent to the outer protective shell 110, while the second layer 220 is disposed against the first layer 210 and in contact with the wearer's head.

As mentioned herein, the first layer 210 may be in the form of a copolymer honeycomb matrix impact absorbing layer. The lightweight copolymer honeycomb matrix acts as a "crash cushion" providing impact absorbing protection for the second layer.

Second layer 220 may be in the form of a non-newtonian foam pad. Many different non-newtonian foams may be used so long as they are suitable for the intended application described herein. Suitable materials for second layer 220 are described herein and include polyurethane foam.

The second layer 220 may be in the form of a single layer or the second layer 220 may itself be comprised of multiple layers (e.g., a laminate formed from multiple foam layers). More specifically, second layer 220 may be a multi-layer non-Newtonian foam pad. For example, second layer 220 may be formed from two or more discrete layers of non-Newtonian foam, where each layer has different material properties. In one exemplary embodiment, the second layer 220 includes three discrete foam layers bonded to each other and having different densities. In particular, the density of the three layers increases gradually in the direction from the inside towards the outside of the helmet. In other words, the innermost foam layer in contact with the wearer's head has the lowest density, while the outermost foam layer in contact with the first layer 210 has the highest density (while the middle foam layer has a density between these two densities).

The multi-layer foam pad (second layer 220) employs varying densities that have been optimized for fit and comfort. Contoured (conforming) non-newtonian foams allow the force on impact to dissipate immediately to dissipate energy, especially for high speed impacts.

In one embodiment, the multi-layer foam cushion comprises a three-layer foam (e.g., polyurethane foam) laminate. The selected first foam layer has a first thickness and a first density and is laminated to a second foam layer having a second thickness and a second density. The first and second thicknesses may be the same or may be different, and in one example, each of the first and second thicknesses may be about 3mm, and the first density is greater than the second density. The selected third foam layer has a third thickness and a third density and is laminated to the second foam layer. Prior to lamination, the third foam layer may be shaved to impart a pattern on one side of the foam layer, and the shaving step causes the third foam layer to have a variable thickness. For example, the third foam layer may have a thickness that is less than the first thickness and the second thickness (e.g., a variable thickness from 0.5mm to about 2.5 mm). This third foam layer preferably has a different density than the other layers so as to act as a comfort foam as it is positioned next to and in contact with the head of the wearer.

As will be understood from the above description, the outer protective shell 100 helps spread energy (from the applied force) across the entire head, while the impact absorbing structure 200 acts as both an impact cushion and a compress (foam) and absorbs impact energy. In addition, the multi-layered foam laminate increases impact protection by slowing the speed of the impacted object at different rates of time (rates of time) due to the different densities of foam.

Although the protective headgear is described herein as being used in baseball, the headgear may be used in softball sports, and may be used in other sports where head protection is desired as well.

The protective headgear described herein provides not only the desired protection, but also a number of other advantages. More specifically, protective headgear 100 is based on a verified cap form factor and is designed to provide good ventilation and a secure fit. The protective headgear may be configured to protect the wearer's vulnerable temple and facial options. The various structures described and illustrated herein utilize rigid edges to provide both temple protection and frontal protection on both sides. In one embodiment, full ear protection is provided for the pitch side. Face protection is provided by an optional eye shield.

As discussed herein, many of the features and actual configurations of headgear may be customized to a particular user. For example, a 3D anatomical scan may be performed, the temple and ear protection described herein may be customized, and there are also customization options for the eyes, nose, and overall facial protection. Thus, the construction of the headwear may be part of a computer-implemented process in which certain anatomical data is first collected by a computer system, and then a graphical representation of the user's head is created using software, such as a 3D modeling program. The various components of the present headgear may be modeled from the graphical representation and then shaped to provide a custom fit headgear to the user.

In one exemplary embodiment, protective headgear 600 has the following specifications:

thickness: -0.7 "

Weight: between about 10 and 12 ounces based on head size.

Protection: laboratory tests have shown that Half-caps pass the american sports equipment standards committee (NOCSAE) standard at a minimum of 85 mph.

Although the present invention has been described in connection with certain embodiments thereof, the invention is capable of being embodied in other forms and using other materials and structures. Accordingly, the invention is defined by the detailed description in the appended claims and their equivalents.

Claims (24)

1. A protective headgear for a baseball or softball fielder comprising:

a rigid outer protective shell having a front, a first side, an opposing second side, and an edge extending outwardly from the front, wherein the outer protective shell has a top opening and a rear opening defined between a first free end of the first side and a second free end of the second side;

an impact absorbing material disposed along an inner surface of the outer protective shell; and

an inner cap for wearing under the outer protective shell, the inner cap being formed of a breathable material.

2. The protective headgear of claim 1, wherein the outer protective shell has symmetrical temple guards formed as part of the first and second side portions, respectively.

3. The protective headgear of claim 1, wherein the outer protective shell has asymmetric temple guards formed as part of the first and second side portions, respectively.

4. The protective headgear of claim 3, wherein the first side includes a reinforced temple guard having a bottom edge to fit under the ear of the wild hand and configured to cover at least a majority of the ear.

5. The protective headgear of claim 4, wherein the enhanced temple guard includes an opening for placement over an ear.

6. The protective headgear of claim 1, further comprising a closure mechanism for selectively closing and opening the first and second side portions relative to each other using a single hand.

7. The protective headgear of claim 6, wherein the closure mechanism includes a ratchet mechanism operable to draw the first and second free ends toward and away from each other.

8. The protective headgear of claim 7, wherein the closure mechanism extends across the rear opening.

9. The protective headgear of claim 1, wherein the impact absorbing material comprises a single layer of material.

10. The protective headgear of claim 1, wherein the impact absorbing material comprises at least two layers of material.

11. The protective headgear of claim 10, wherein the at least two layers include a first layer for placement against an inner surface of the outer protective shell and a second layer for placement against an outer surface of the first layer.

12. The protective headgear of claim 4, wherein the impact absorbing material is disposed on the enhanced temple guard but does not extend under the ear.

13. The protective headgear of claim 1, further comprising an eyeplate attached at a first end to the first side and at an opposite second end to the second side.

14. The protective headgear of claim 13, wherein the ocular shield plate is detachably connected to the outer protective shell.

15. The protective headgear of claim 1, wherein the outer protective shell comprises a carbon fiber/aramid composite material.

16. The protective headgear of claim 1, wherein the outer protective shell is generally U-shaped with the first and second sides defining legs of the U-shape.

17. The protective headgear of claim 1, wherein the inner cap comprises a stretchable rimless cap formed from a mesh material.

18. The protective headgear of claim 11, wherein the first layer has a thickness of between about 4mm and about 15mm, and the second layer has a thickness of between about 2mm and 6mm, and the outer protective shell has a thickness of between about 1mm and about 5 mm.

19. The protective headgear of claim 1, wherein the left side portion includes a bottom edge that is curved to extend over and around the respective ear.

20. A protective headgear for a baseball or softball fielder comprising:

a rigid outer protective shell generally U-shaped and defined by a first flexible flap extending rearwardly and terminating in a first free end, an opposing second flexible flap extending rearwardly and terminating in a second free end, and an edge, wherein the outer protective shell is open between the first and second flexible flaps along a top and a rear thereof;

an impact absorbing material disposed along an inner surface of the outer protective shell; and

a mechanism for adjusting the size of the outer protective shell.

21. A protective headgear for a baseball or softball fielder comprising:

a rigid outer protective shell; and

an impact-absorbing structure disposed along an inner surface of the outer containment shell, wherein the impact-absorbing structure comprises: a copolymer honeycomb matrix impact absorbing layer coupled to the inner surface of the outer protective shell along a first surface and a non-newtonian foam layer coupled to a second surface of the copolymer honeycomb matrix impact absorbing layer.

22. The protective headgear of claim 21, wherein the non-newtonian foam layer comprises two or more discrete foam layers.

23. The protective headgear of claim 22, wherein the non-newtonian foam layer comprises three foam layers, the foam layers having a different density than the other foam layers.

24. The protective headgear of claim 23, wherein the density increases progressively in a direction toward the outer protective shell.