Patent Application
20160271482
The present invention relates to sports equipment and more particularly, relates to protective headgear that is designed to be worn by a baseball or softball fielder, especially a pitcher, to protect the fielder's head and face from being struck by a batted ball.
Baseball is known as America's pastime. Baseball is a bat-and-ball game played between two teams of nine players each who take turns batting and fielding. The offense attempts to score runs by hitting a ball thrown by the pitcher with a bat and moving counter-clockwise around a series of four bases, namely, first, second, third and home plate. A run is scored when a player advances around the bases and returns to home plate.
Fielders wear gloves to assist in catching a hit ball and typically wear soft brim caps as part of their uniforms. Batted balls can reach high speeds and therefore, there is a desire to provide the fielders with head and face protection from such batted balls.
In one embodiment of the present invention, a protective headgear for a baseball or softball fielder (e.g., a pitcher thereof) is provided and includes a rigid outer protective shell that has a front portion, a first side portion, an opposing second side portion and a brim that extends outwardly from the front portion. The outer protective shell has a top opening and a rear opening that is defined between a first free end of the first side portion and a second free end of the second side portion. As a result, the protective headgear does not completely circumscribe the fielder's head. As described herein, the top opening allows the head to more easily “breathe” (allowing air and moisture transfer) and the rear opening allows the size (circumference) of the outer protective shell to be altered so as to ensure a proper snug fit is achieved regardless of the size of the fielder's head.
The protective headgear also includes an impact absorption material disposed along an inner surface of the outer protective shell and also an inner cap to be worn beneath the outer protective shell. In at least some of the embodiment, the headgear includes an impact absorption region that is formed as a multilayer structure formed of two or more energy absorbing materials. The inner cap is formed of a breathable material and can be in the form of a skull cap.
The protective headgear 100 includes a number of different parts that are assembled to form the complete product and more specifically, the protective headgear 100 includes an outer protective shell 110. The outer protective shell 110 does not completely enclose the user's (player's) head but instead is designed such that it has an open top and an open rear. More specifically, the outer protective shell 110 has a front portion 120, a first side portion 130, an opposing second side portion 140 and a brim 150 that extends outwardly from the front portion 120. The outer protective shell 110 has a top opening 160 and a rear opening 170 that is defined between a free end 132 of the first side portion 130 and a free end 142 of the second side portion 140.
From a top view, the outer protective shell 110 generally has a U-shape in that it has an open rear as discussed above (i.e., the legs of the U are not continuous with one another). This U-shape allows for flex to accommodate varies head sizes and thus, serves as mechanism to ensure a proper fit with the user (fielder). The outer protective shell 110 has a top edge 111 that defines the top opening 160 and extends from the free end 132 of the first side portion 130 across the front portion 120 to the free end 142 of the second side portion 140. The top edge 111 is also U-shaped. A bottom edge 113 of the outer protective shell 110 is defined by and extends across the first side portion 130, the brim 150, and the second side portion 140.
As shown in the views of
The first side portion 130 can be thought of as being the left side earflap and the second side portion 140 can be thought of as being the right side earflap. When the protective headgear 100 is intended for use by a baseball pitcher, one of the first and second side portions 130, 140 can offer additional protection in view of the normal mechanics and motion of pitcher as the ball is released as shown and described herein.
It will also be appreciated that the first and second portions 130, 140 can, in one embodiment, be both modular and configurable so as to allow the first and second portions 130, 140 to be selected in view of certain parameters, such as the physical characteristics of the user (fielder). In this embodiment, the portions 130, 140 can thus be detachably coupled to the main (base) portion of the headgear. For example, a mechanical fit, such as a releasable snap-fit, can be provided between the portions 130, 140 and the main (base) portion to allow the user to select one portion 130 from amongst a set of portions 130 and one portion 140 from amongst a second of portion 140. In addition, other parts, including a rear tensioning mechanism for tightening the headgear can also be constructed so as to be modular in nature. Various types of exemplary rear tensioning mechanism are described herein.
Generally, the pitcher winds up and delivery begins when the pitcher brings his arms together in front of his body (this is called coming set). After coming set, the pitcher takes a step toward home and delivers the pitch. Typically, pitchers from the set use a high leg kick, thus lunging toward home in pitching; a pitcher may instead release the ball more quickly by using the slide step, quickly stepping directly and immediately toward home and pitching. After releasing the ball, the pitcher assumes a fielding position. The natural body movement of the pitcher exposes one side of the head more than the other side 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 a ball strike and similarly, if the pitcher is a left-handed pitcher, the left side of the head is more exposed.
As described below,
More specifically, for purpose of illustration only,
For a right-handed pitcher, the left side (first side) portion 130 does not cover the left ear of the player but instead, the ear is left exposed as shown in
As mentioned, for a right-handed pitcher, the right side (second side) portion 140 includes enhanced protection in that the right side portion 140 hangs lower and substantially covers the right ear as shown in
As shown in the figures, the right side portion 140 can be configured such that it also extends across an upper portion of the jaw. The illustrated ear vent 141 has a generally triangular or elongated shape and extends forward towards the face. However, it will be understood that the ear vent 141 can have any number of other shapes and can come in different sizes too.
The left side portion 130 can be thought of as being a left wing that extends rearwardly and the right side portion 140 can be thought of as being a right wing that extends rearwardly and is disposed across from the left side portion 130. The left and right wings 130, 140 are flexible in nature to allow the protective shell 110 to be fitted to different sized heads and allow the closing and opening of the protective headgear 100 as described herein. In other words, the flexible nature of the two wings 130, 140 allows these two structures to be drawn toward one another to tighten the headgear 100 or they can further separated apart to loosen the headgear 100.
The outer protective shell 110 can be formed as a single piece (part) using traditional manufacturing techniques, such as a molding process. The outer protective shell 110 can be formed of any number of rigid materials that are suitable for the present application. In one exemplary embodiment, the outer protective shell 110 is formed of a composite material and more particularly, is formed of a carbon fiber/aramid composite for the purposed of dispensing impact energy across a field larger than the initial impact location. For example, the outer protective shell 110 can be made of a carbon fiber/aramid composite that has a thickness between about 1 mm and about 5 mm.
In one exemplary embodiment, the outer protective shell is formed of three layers of carbon fibers. For example, three layers of carbon weave cloth is combined with (embedded in) an epoxy resin to create the shell. The three layers can be laid out into an aluminum mold, are sandwiched against each other with an interior removable silicon “plug”, and then baked together so that the epoxy resin flows through the three layers of carbon fiber fabric. Once it cools, the epoxy resin becomes hard and the three layers of carbon fiber fabric act as shock barriers dispersing impact energy.
As described herein, the outer protective shell 110 can have a variable thickness (e.g., between 1.0 mm and 1.5 mm). Two impact zones are formed to have a thickness of 1.5 mm and the rest of the shell is formed to have a thickness of 1.0 mm. The two impact zones that are 1.5 mm thick are defined as the “front” and “side” impact zones as described herein and as defined in the NOSCAE test protocol. The increased localized thickness allows the headgear 100 to pass testing in these two impact zones and the rest of the shell 110 is thinner (1.0 mm) to keep weight to a minimum.
It will be appreciated that other materials can be used to form the outer protective shell 110 and in particular, the shell 110 can be formed as a non-composite structure. In some applications, the shell 110 can be formed of polycarbonate or other suitable material. The shell 110 can also be constructed such that it includes a bonded interlayer of a honeycomb or copolymer extruded material. In addition, the shell 110 can be constructed such that includes an insert molded EPS foam substructure chemically bonded (or otherwise bonded) to the outer shell 110.
The protective headgear 100 includes an impact absorption structure (material) 200 that is disposed along and is secured to an inner surface of the outer protective shell 110. The impact absorption structure (material) 200 can be formed as a single layer from a single material or can be formed of two or more layers that are formed of different materials as shown in the exemplary figures. The impact absorption structure 200 is intended to provide primary impact absorption. Each of the structures (materials) that form the headgear provide a level of impact absorption; however, the primary area of the impact absorption is the structure 200. The bond between the shell 110 and the structure 200 (e.g., a honeycomb shaped structure as described herein) can be of a high strength to help engage the material of the structure 200 upon impact (e.g., help engage the cell structure of the honeycomb material upon impact).
In the illustrated embodiment, the impact absorption structure 200 is formed of two layers of material that offer the desired impact absorption properties. For purpose of illustration only, the figures show a solid block of impact absorption structure 200 and do not differentiate between the two layers that make up the structure 200. Exemplary materials to form the two layered structure 200 are shown in
For example, the first impact absorption layer 210 can be formed of a thermoplastic honeycomb comprised of a co-extruded polycarbonate (PC) for energy absorption. This structure provides uniform mechanical properties due to its circular cell structure, and offers high compressive strength in a low-density material, decreasing transmitted force and peak g-force acceleration. The honeycomb is an efficient energy absorber, which is vital to impact protection, and is highly breathable. Depending on cell size and polymer density compression strength (DIN 53421), the material has been tested and such testing has resulted in durability against 101 to 522 psi (0.7 to 3.6 MPa), compression strength increases with smaller cell size. The intercellular connection is achieved without the use of glues of adhesives, but rather by thermal welding, which increases visual and performance consistency. Individual tubes are co-extruded with an inner and outer layer, each comprised of 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 melting the exterior layer of each tube providing a thermo-weld between all adjacent tubes. The tubes are then cross cut into sheets. The welded honeycomb sheets can be further processed into finished dimensions and shaped parts with milling, thermoforming, cutting, profiling, lamination, plating, etc.
In one exemplary embodiment, the first impact absorption layer 210 can have a thickness of between about 3 mm to about 15 mm (e.g., 10 mm thick). The footprint of the first impact absorption layer 210 can be the same or similar to the footprint of the outer protective shell 110. Any number of means can be used to attach the first impact absorption layer 210 to the inner surface of the outer protective shell 110. For example, an adhesive or other bonding agent (e.g., pressure sensitive adhesives) or mechanical fasteners can be used to attach the first impact absorption 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 absorption layer 210 can be an impact absorption material that can be provided in the form of a flexible plastic cushioning material layer that can provide a nearly linear force-deflection curve which allows for maximum comfort throughout the compression and shock cycle. The flexible plastic cushioning material layer can be formed of a plurality of molded flexible high polymer resin members comprising of inwardly directed indentations. The first layer 210 can have a thickness of about 13 mm. It will be understood that the first layer 210 can 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
The second layer 220 can be in the form of a protective padding product that can be in the form of a urethane foam material that is formed using breathable, anti-microbial, open or closed cell technology for the purpose of providing impact protection and comfort. The second layer 220 is shown in
As shown in the figures, the impact absorption structure 200 can cover most of the inner surface of the outer protective shell 110; however, the layer 200 can be eliminated from a portion of the right side portion 140 (for a right-handed pitcher). More specifically, the second section 145 of the right side portion 140 that covers and hangs below the ear can be free of the impact absorption structure 200. The outer protective shell 110 still covers these areas and thus offers protection. The absence of structure 200 allows sound to travel directly to the ear without significant attenuation from the surrounding structures.
The protective headgear 100 includes a mechanism for adjusting the protective headgear 100 so that a secure fit is formed on the user's head.
In the illustrated embodiment of
The present figures set forth different types of adjustment mechanisms that can be used including some that pull the side portions 130, 140 together using a ratcheting mechanism or the like. For example,
As shown in
Alternatively, an elastic tension band (not shown) can be provided between the side portions 130, 140. In yet another embodiment, the mechanism 300 can be of interchangeable type in that the free ends of the side portions 130, 140 can include a connector or the like for releasably connecting to the mechanism 300 to allow the wearer the option to swap out one mechanism for another mechanism. For example, a ratchet mechanism with complementary connectors at its ends can mate with the connectors at the free ends of the side portions 130, 140 and similarly, an elastic tension band with connectors at its ends can be mated to the connectors at the free ends of the side portions 130, 140. This allows customization of the mechanism 300 that is used to tighten the headgear 100.
Additional adjustment mechanisms can also be used with headgear 100.
The protective headgear 100 is preferably intended to be worn with an inner cap 500 (
Since the inner cap (skull cap) 500 is a separate part, it can be easily removed and cleaned or otherwise processed. This versatility also allows the appearance of the headgear to be slightly altered in that the color and/or indicia on the inner cap can be varied by simply switching the inner cap.
In one embodiment, the inner cap 500 and protective headgear 100 can be constructed such that the inner cap 500 is fixedly, yet releasably, attached (coupled) to the protective headgear 100. In particular, the inner cap 500 can be attached to either the protective shell 110 or even the impact absorption structure 200. Any number of different fastening techniques can be used to attach the inner cap 500 to the protective headgear 100. For example, one or more fasteners (e.g., snaps, hook and loop material, etc.) can 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 and the other half of the fastener pair is associated with the headgear 100 (e.g., the protective shell 110 or the impact absorption structure 200.
In another embodiment, a bead can be formed along the periphery of the inner cap 500 and can be received within a corresponding groove formed in the protective headgear 100 (e.g., the groove can be formed in either the shell 110 or the impact absorption structure 200. To attach the inner cap 500 to the protective headgear 100, the bead is inserted into the groove. To release the inner cap 500, the bead is removed from the groove.
The attachment of the inner cap 500 is not permanent since it is directed to periodically remove the inner cap 500 for cleaning thereof.
It will also be appreciated that the headgear disclosed herein can be customized for a particular person using software that allows measurements to be taken of the user prior to manufacturing. For example, 3D head scanning technology can be used to ensure optimal player fit in that the shape and size of the various parts of the headgear can be made in view of this collected data (measurements).
The protective headgear 100 can include a number of optional accessories.
The ocular shield 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 portion 130, while the second end 404 is attached to the second (right) side portion 140. Any number of different techniques can be used to couple and securely attach the ends 402, 404 to the respective first and second side portions 130, 140. For example, the attachment can be of a detachable type or can be permanent in nature. To attach the ends 402, 404, fasteners 410 or the like can be used. In addition, a mechanical coupling can be used to attach the ocular shield 400 to the outer protective shell. For example, one of the outer protective shell 110 and the ocular shield 400 can include a protrusion and the other of the outer protective shell 110 and the ocular shield 400 can include a slot that receives the protrusion. The slot can include a locking portion into which the protrusion slides to thereby lock and attach the ocular shield 400 to the shell 110.
In addition, as shown in
In one embodiment, the protective headgear 100 includes an outer protective shell 110 and the impact absorption structure 200 which can be in the form of a multi-layer structure as described herein.
As mentioned previously, the outer protective shell 110 can have a variable wall thickness and more specifically, the shell construction is optimized to provide additional protection where the wearer is most vulnerable and is thinner in other less vulnerable regions to minimize weight. In particular, the areas of increased vulnerability are the forehead; the temple(s) region; and the side(s) of the head. In
By varying the thickness of the outer protective shell 110 in a localized manner, the shell 110 provides increased protection in the vulnerable regions, while the less vulnerable areas have reduced thickness, which provides an overall weight reduction in the protective headgear 600.
The outer protective shell 110 can be formed of the same materials as the outer protective shell 110 and therefore, can be formed of a composite material as discussed herein.
As discussed herein, the impact absorption structure 200 can be formed of the first layer 210 and the second layer 220. The first layer 210 is adjacent the outer protective shell 110, while the second layer 220 is disposed against the first layer 210 and is in contact with the head of the wearer.
As mentioned herein, the first layer 210 can be in the form of a coploymer honeycomb matrix impact absorption layer. The lightweight copolymer honeycomb matrix acts as a “crumple zone,” providing the second layer of impact absorption defense.
The second layer 220 can be in the form of a non-Newtonian foam liner. Any number of different non-Newtonian foam materials can be used so long as they are suitable for the intended application described herein. Suitable materials for the second layer 220 are described herein and include urethane foams.
The second layer 220 can be in the form of a single layer or the second layer 220 can itself be comprised of multiple layers (e.g., a laminate formed of multiple foam layers. More specifically, the second layer 220 can be a multi-layer non-Newtonian foam liner. For example, the second layer 220 can be formed of two or more discrete layers of non-Newtonian foam with each layer having different material characteristics. In one exemplary embodiment, the second layer 220 comprises three discrete foam layers that are bonded to one another and have varying densities. In particular, the densities of the three layers progressively increase in a direction from the inside of the helmet toward the outside. In other words, the density of the innermost foam layer that contact the wear's head has the lowest density, while the outermost foam layer that is in contact with the first layer 210 has the highest density (and the intermediate foam layer has a density between these two densities).
The multilayer foam liner (second layer 220) utilizes varying densities, which have been optimized for fit and comfort. The contouring non-Newtonian foam instantly dissipates force upon impact to disperse the energy, especially for high-speed impacts.
In one embodiment, the multilayer foam liner comprises a three layer foam (e.g., urethane foam) laminate. A selected first foam layer has a first thickness and a first density and is laminated to a second foam layer that has a second thickness and a second density. The first and second thicknesses can be the same or can be different and in one example, each of the first and second thicknesses can be about 3 mm and the first density is greater than the second density. A 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 can be skived so as to impart a pattern on one side of the foam layer and the skiving step results in the third foam layer having a variable thickness. For example, the third foam layer can have a thickness that is less than the first and second thicknesses (e.g., a variable thickness from 0.5 mm 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 due to its positioning next to and in contact with the wearer's head.
As will be appreciated from the foregoing discussion, the outer protective shell 100 helps to spread the energy (from an applied force) across the whole of the head, while the impact absorption structure 200 acts as both a crumple zone and compresses (foam) and absorbs the impact energy. Further, the multi-layer foam laminate adds to impact protection by slowing down the speed of the impacted object at different rates of times due to the different density foams.
While the protective headgear is described herein as being for use in the sport of baseball, the headgear can be in the sport of softball and also can equally be used in other sports in which head protection is desired.
The protective headgear described herein not only provides the desired protection but also provides a number of other advantages. More specifically, the protective headgear 100 is based on a proven cap form factor and is designed to provide good ventilation and a secure fit. The protective headgear is configurable with options to protect vulnerable temples and the face of the wearer. The various constructions described and illustrated herein, provide temple protection on both sides and frontal protection with the rigid brim. In one embodiment, full ear protection is provided for the pitching side. Facial protection is provided with the optional ocular shield.
As discussed herein, many of the features and the actual construction of the headgear can be customized for a particular user. For example, 3D anatomical scanning can be performed, the temple and ear protection described herein can be customized and there also customization options for the eye, nose, and full face protection. Thus, the construction of the headgear can be part of a computer implemented process in which certain anatomical data is first collected by a computer system and then software, such as a 3D modeling program, can be used to create a graphic representation of the user's head. From this graphic representation, the various components of the present headgear can be modeled and then formed so as to provide the user with a custom fit headgear.
In one exemplary embodiment, the protective headgear 600 has the following specifications:
Weight: Between about 10 and 12 ounces based on head size.
Protection: Laboratory testing shows that the Half Cap passes the National Operating Committee on Standards for Athletic Equipment (NOCSAE) standard at a minimum of 85 mph.
While the invention has been described in connection with certain embodiments thereof, the invention is capable of being practiced in other forms and using other materials and structures. Accordingly, the invention is defined by the recitations in the claims appended hereto and equivalents thereof.
This application is based on and claims priority to U.S. Provisional Patent Application 62/134,337, filed Mar. 17, 2015, and U.S. Provisional Patent Application 62/294,444, filed Feb. 12, 2016, the entire contents of each is incorporated by reference herein as if expressly set forth in its respective entirety herein.
| Number | Date | Country | |
|---|---|---|---|
| 62134337 | Mar 2015 | US | |
| 62294444 | Feb 2016 | US |
