AU2004202011A1

AU2004202011A1 - Headgear and method of construction

Info

Publication number: AU2004202011A1
Application number: AU2004202011A
Authority: AU
Inventors: Richard Andrew Cathro; John Rex Dench; Miles Digby Rapley
Original assignee: PROTECTIVE SPORTS APPAREL Ltd
Current assignee: PROTECTIVE SPORTS APPAREL Ltd
Priority date: 2003-05-16
Filing date: 2004-05-12
Publication date: 2004-12-02
Also published as: GB2401531B; GB0410836D0; NZ525927A; GB2401531A

Description

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AUSTRALIA

PATENTS ACT 1990 COMPLETE

SPECIFICATION

FOR A STANDARD PATENT

ORIGINAL

Name of Applicant: Actual Inventors: Address for Service:

CCN:

Invention Title: Protective Sports Apparel Limited Richard Andrew Cathro and Miles Digby Rapley and John Rex Dench Baldwin Shelston Waters MARGARET STREET SYDNEY NSW 2000 3710000352 HEADGEAR AND METHOD OF CONSTRUCTION The following statement is a full description of this invention, including the best method of performing it known to us:- File: 42610AUP00 500352229_1 .DOC5844 HEADGEAR AND METHOD OF CONSTRUCTION FIELD OF THE INVENTION The invention relates to headgear for the protection of a user's head. In particular, the invention relates to headgear useful for protecting the head of a participant in sports and other activities where physical contact between participants is possible or even likely.

BACKGROUND

Headgear made from a soft material are used extensively to protect the heads of players of contact sports. For example, headgear is commonly used by wrestlers and rugby players. However, the physical nature of these activities can make the wearing of headgear uncomfortable due to poor ventilation of the head and the corresponding loss of cooling. Even in headgear with apertures designed to increase ventilation small apertures alone provide only limited ventilation over a small area of the user's head.

In non-contact sports, such as cycling, headgear made from hard materials with improved ventilation is well-known. Cycle helmets commonly use speed through the air to assist air to circulate through the helmet.

Known headgear that are constructed of a soft or resilient material so that they fit snugly with the head of a user tend to suffer from ventilation difficulties.

It is an object of the invention to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative.

STATEMENTS OF INVENTION In a first aspect, the invention provides headgear constructed substantially of resilient material, having an inner surface and an outer surface and a plurality of apertures through the resilient material providing conduits between the inner surface and the outer surface, wherein the inner surface has a plurality of channels provided therein arranged to effect ventilation around the user's head, at least some of the channels communicating with at least some of the apertures.

In a second aspect, the invention provides a method of protecting the head of a user, comprising the wearing of headgear of the first aspect of the invention.

In a third aspect, the invention provides a method of constructing headgear, comprising the steps of: a) moulding a top portion formed of resilient material between first moulds; b) moulding a bottom portion formed of resilient material between second moulds; wherein internal channels -are formed in the top and/or bottom portions; c) creating conduits from an inner surface to an outer surface, at least some of said conduits communicating with at least some of the internal channels; and d) joining the top and bottom portions to form the headgear..

In a fourth aspect the invention provides a method of constructing headgear, comprising forming a shell of resilient material having internal channels and conduits from an inner surface to an outer surface, at least some of the conduits communicating with at least some of the internal channels.

Unless the context clearly requires otherwise, throughout the description and the claims, the words "comprise", "comprising", and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of "including, but not limited to".

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BRIEF DESCRIPTION OF DRAWINGS The invention will be described by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a perspective view of headgear according to the invention; Figure 2 is a top view of the headgear of Figure 1; Figure 3 is a back view of the headgear of Figure 1; Figure 4 is a second perspective view of the headgear of Figure 1; Figure 5A is a first view of a circular aperture and a teardrop shaped depression in the outer surface of the headgear of Figure 1; Figure 5B is a first section through the aperture and depression of Figure Figure 5C is a second section through the aperture and depression of Figure Figure 6A is a first view of a slot shaped aperture and an elongate depression in the outer surface of the headgear of Figure 1; Figure 6B is a first section through the aperture and depression of Figure 6A; Figure 6C is a second section through the aperture and depression of Figure 6A; Figure 7 is an external pattern view of the bottom portion of the headgear of Figure 1; Figure 8 is an internal pattern view of the bottom portion of the headgear of Figure 1; Figure 9 is an external pattern view of the top portion of the headgear of Figure 1; and

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Figure 10 is an internal pattern view of the top portion of the headgear of Figure 1.

DETAILED

DESCRIPTION

Referring now to Figure 1, the headgear 100 is formed from two pieces, a top portion 101 and a bottom portion, 102. The top portion 101 and the bottom portion 102 are stitched together along join 120. The headgear 100 has an inner surface 103 and an outer surface 104. The headgear 100 is constructed substantially of resilient material.

The bottom portion 102 includes ear apertures 150 and a chinstrap 151 for retaining the headgear on the head during use. Preferably, the chinstrap 151 uses a Velcro fastening, although other fastenings may also be suitable. Each ear aperture 150 may consist of a single hole of a suitable shape! or a number of holes of a suitable shape. For example, in Figure 1, each ear aperture 150 consists of a number of slots.

The top portion 101 comprises a central region 111 with five radiating flaps 110, as will be described more fully below. Although a construction utilising 5 flaps is preferred it will be appreciated that different numbers of flaps may be employed.

The headgear also includes a plurality of apertures 130, 140 which pass through the headgear, forming conduits from the inner surface to the outer surface. Each of the apertures 130, 140 has an opening to the inner surface 103 and an opening to the outer surface 104.

The apertures 130 are slot shaped, and preferably the outer surface openings 133 thereof are situated within elongate, generally parallel-sided depressions 131 in the outer surface 104. The apertures 140 are circular in cross-section, and preferably the outer surface openings 143 thereof are situated within teardrop shaped depressions 141. Many other shapes of aperture and depression may be suitable. Also, apertures with outer surface openings that are not situated within depressions are within the scope of the invention.

The apertures communicate with channels in the inner surface of the headgear, as will be described below.

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Figure 2 shows a top view of the headgear of Figure 1. The top portion of the headgear, as described above, comprises a central region 111 with five radiating flaps 110. The flaps 110 are separated by slits 21 C0 and 220. The slits 210 are defined by slit edges 211 and 212, which end at join 120, while the slit 220, defined by slit edges 221 and 222, extends to the bottom of the headgear. Preferably, the width of the slit 220 can be adjusted by loosening or tightening a lacing arrangement 240 such that the circumference 230 of the headgear can be altered. In this way the headgear can be adjusted to the size of the head of a user. Other methods of joining the sides of the slit may also be suitable. For example, a Velcro type fastening or an elastic arrangement could also be used. Here we take the circumference to include the width of the slit 220 along the lacing arrangement 240.

Figure 3 shows a rear view of the headgear of Figure 1. The lacing arrangement 240 consists of a lace 320 passed through a plurality of holes 310 in sections 331 and 332 adjacent to the slit edges 221 and 222.

Figure 4 is another view of the headgear of Figure 1. In Figure 4 the internal channelling of the headgear is visible. A number of channels 410 are formed on the inner surface 103.

The inner surface openings 132, 142 (shown in Figures 5B, 5C, 6B and 6C) of apertures 130, 140 communicate with channels on the inner surface 103. Preferably, the inner surface openings 132, 142 of apertures 130 and 140 are situated within the channels 410 on the inner surface. The inner surface openings could also be situated partially within the channels on the inner surface or directly adjacent to the channels on the inner surface.

In Figure 4, the headgear 100 is shown with the chinstrap 151 disengaged. To engage the chinstrap 151, the end 152 of the chinstrap 151 is passed through the aperture 420. The chinstrap 151 is than doubled back upon itself and secured using a Velcro fastening 153 (not visible in Figure 4).

Figure 5A shows a first view of one of the teardrop depressions 141 with a circular aperture 140, of the headgear 100 of Figure 1. Figure 5B shows a first section through the headgear along the line B-B shown in Figure 5A. The outer surface opening 143 of a circular aperture 140 is situated within a teardrop shaped depression 141 in the outer surface 104. The aperture 140 passes through the resilient material 105 and its inner surface opening 142 is situated within channel 410 in the inner surface 103. Figure shows a second section through the headgear, along the line C-C shown in Figure Figure 6A shows a first view of one of the elongate, generally parallel-sided depressions 131 with a slot shaped aperture 130, of the headgear 100 of Figure 1. Figure 6B shows a third section through the headgear along the line D-D shown in Figure 6A. The outer surface opening 133 of the aperture 130 is situated within an elongate depression 131 in the outer surface 104. The aperture 130 passes through the resilient material 105 and its inner surface opening 132 is situated within channel 410 in the inner surface 103. Figure 6C shows a fourth section through the headgear along the line E-E shown in Figure 6A.

Preferably, the depressions 131 and 141 have lengths which are within the range 20 to mm, ideally about 40 mm. Preferably, the depressions 131 and 141 have widths in the range 5 to 30 mm, ideally about 15 mm.

Preferably, each slot shaped aperture 130 is situated substantially centrally within an elongate depression 131 and each circular aperture 140 is situated towards the wider end of a teardrop shaped depression 141. Preferably, the circular apertures 140 have diameters in the range 5 to 15 mm, ideally about 9 mm.

Preferably the slot shaped apertures 130 have lengths in the range 15 to 45mm, ideally about 25 mm and widths in the range 2 to 20 mm, ideally about 3 mm.

The apertures 130 and 140 act as inlet apertures or exhaust apertures. The depressions in the outer surface are shaped such that air flow at the outer surface causes a pressure difference at the outer surface openings of the apertures relative to the pressure within the channels. Airflow at the outer surface could be caused either by wind or by movement of the headgear through the air. Thus, air tends to circulate through the apertures because of the pressure difference. When the airflow at the outer surface is substantially perpendicular to the outer surface, this airflow will tend to push air through the apertures and into'the channels. When the airflow is substantially parallel to the outer surface air may tend to be drawn from the channels towards the outer surface. These effects encourage circulation within the channels, and effect ventilation around the user's head.

The apertures should sufficiently allow circulation of the air, whilst not reducing protection of the user's head.

Figure 7 shows a pattern view of the outer surface of the bottom portion 102 of headgear of Figure 1, showing the teardrop shaped depressions 141 and the ear apertures 150.

The chinstrap 151 and the apertures 140 are not shown. Figure 8 shows a similar pattern view of the inner surface of the bottom portion of the headgear of Figure 1, showing the channels 410 and the ear apertures 150.

Figure 9 shows a pattern view of the outer surface of the top portion 101 of the headgear of Figure 1, showing teardrop shaped depressions 141 and elongate depressions 131.

Figure 10 shows a pattern view of the inner surface of the top portion of the headgear of Figure 1, showing the channels 410.

Preferably, the resilient material comprising the top and bottom portions of the headgear is resilient foam, although other materials such as leather, for example, may be suitable.

Ideally, ethyl vinyl acetate (EVA) or polyethylene closed cell foam is used, since they provide greater comfort than most other resilient materials. Alternatively, a gel-filled material could be used. For example, closed cell foam sheets of about 2 mm thickness could be joined together with gel bladders between them, or gel could be injected between two closed cell foam sheets. Rubber or plastic sheets could also be used in place of the closed cell foam sheets.

The resilient material may have a density of between 30 and 100 kg per cubic metre, preferably within the range 30 to 60 kg per cubic metre, ideally about 45 kg per cubic metre. The resilient material may have a thickness of between 5 and 20 mm, preferably in the range 8 to 12 mm.

An inner fabric layer may be fixed to the inner surface of the headgear and an outer fabric layer may be fixed to the outer surface of the headgear. Preferably, the fabrics used should not be significantly affected by sunlight, water, dirt, sweat, soaps or detergents.

Ideally, the inner fabric is cotton or a similar fabric for maximum comfort and sweat dissipation and the outer fabric is nylon or lycra for maximum UV resistance, wear and

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colour fastness. It is preferred that the resilient material and fabric layers together are less than 13 mm thick.

The headgear described abowve can conveniently be made by thermo moulding. Moulding in two dimensions, as required by the present design, is more difficult than moulding in only one dimension. In the preferred process, closed cell foam laminated on one side with nylon or lycra and on the other side with cotton, and having a thickness of about 15 mm is moulded between at least two moulds, at high temperature. The closed cell foam may be provided to the moulding stage in sheet form. The moulds may be made of wood, an alloy or another suitable material.

The fabric layers can be attached to the closed cell foam either by adhesion or heat bonding, although other methods of attachment may also be suitable. After the moulding, the closed cell foam should ideally have a thickness of around 10 mm. The channels, depressions and apertures are created by the shape of the moulds. Alternatively, the apertures could be created by punching after the moulding process. The edges of the headgear or of the portions of the headgear can be defined by cutting during the moulding process, where the moulds include cutting edges, or before or after the moulding process.

Preferably, the top and bottomrn portions of the headgear are moulded separately and are then joined, preferably by stitching, although other methods of joining may also be suitable.

The headgear could also be made by injection moulding, either in a Single piece or in a number of portions. In this case cutting to shape may not be necessary. Preferably a slightly elastic material would be used if the headgear were made in a single piece, so that adjustment means would be unnecessary.

Headgear according to the invention is suitable for use in many sports. For example, the headgear could be worn by players of rugby union, rugby league, Australian Rules football and Gaelic football and by windsurfers, surfers, and kite-surfers. In some cases, the headgear worn in a particular sporting code must meet regulations imposed by a governing body, and it is anticipated that headgear according to the invention could be made from a variety of materials, materials of different thicknesses etc. in order to meet these requirements.

While the present invention has been illustrated by the description of the embodiments thereof, and while the embodiments have been described in detail, it is not the intention of the Applicant to restrict or in anyway limit the scope of the appended claims to such detail.

Additional advantages and modifications will readily appear to those skilled in the art.

Therefore, the invention in its broader aspects is not limited to the specific details, representative apparatus and method, and illustrative example shown and described.

Accordingly, departures may be made from such details without departure from the spirit or scope of the Applicant's general inventive concept.

Claims

1. Headgear constructed substantially of resilient material, having an inner surface and an outer surface and a plurality of apertures through the resilient material providing conduits between the inner surface and the outer surface, wherein the inner surface has a plurality of channels provided therein arranged to effect ventilation around a user's head, at least some of the channels communicating with at least some of the apertures.

2. Headgear as claimed in claim 1, wherein each of the apertures has an inner surface opening, and at least some of the inner surface openings are situated at least partly within channels in the inner surface.

3. Headgear as claimed in claim 1 or claim 2, wherein each of the apertures has an outer surface opening, and at least some of the outer surface openings are situated at least partially within depressions in the outer surface.

4. Headgear as claimed in claim 3, wherein at least some of the outer surface openings are situated entirely within the depressions in the outer surface.

Headgear as claimed in claim 3 or claim 4, wherein at least some of the depressions are elongate.

6. Headgear as claimed in claim 3 or claim 4, wherein at least some of the depressions are tear-drop shaped.

7. Headgear as claimed in any one of the preceding claims, wherein at least some of the apertures are circular in cross-section.

8. Headgear as claimed in any one of the preceding claims, wherein at least some of the apertures are slots. I 12

9. Headgear as claimed in any one of the preceding claims, formed substantially from two pieces of resilient material.

Headgear as claimed in any one of the preceding claims, wherein the headgear includes means for adjusting the circumference of the headgear.

11. Headgear as claimed in any one of the preceding claims, wherein the resilient material is resilient foam.

12. A method of protecting the head of a user, comprising the wearing of headgear as claimed in any one of claims 1 to 11.

13. A method of constructing headgear, comprising the steps of: a) moulding a top portion formed of resilient material between first moulds; b) moulding a bottom portion formed of resilient material between second moulds; wherein internal channels are formed in the top andlor bottom portions; c) creating conduits from an inner surface to an outer surface, at least some of said conduits communicating with at least some of the internal channels; and d) joining the top and bottom portions to form the headgear.

14. A method as claimed in claim 13, wherein the resilient material is in sheet form. A method as claimed in claim 13 or claim 14, wherein the conduits are formed by punching apertures in the resilient material.

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16. A method as claimed in any one of claims 13 to 16, wherein during moulding depressions are formed in the outer surface.

17. A method of constructing headgear claimed in any one of claims 1 to 11, wherein the headgear is formed substantially in a single piece by injection moulding.

18. A method of constructing headgear, comprising forming a shell of resilient material having internal channels and conduits from an inner surface to an outer surface, at least some of the conduits communicating with at least some of the internal channels.

19. Headgear substantially as herein described with reference to any one of the embodiments of the invention illustrated in the accompanying drawings. A method of constructing headgear substantially as herein described with reference to any one of the embodiments of the invention illustrated in the accompanying drawings. DATEDthis 12th Day of May, 2004 BALDWIN SHELSTON WATERS Attorneys for Protective Sports Apparel Limited