HEADGEAR AND METHOD FOR MANUFACTURING THE SAME

Abstract

The present invention relates to a new headgear for protecting the head of a person, the new headgear comprising: a base body; a plurality of high frequency impact absorbing elements embedded or adhered to the base body; a cover element that surrounds the base body and the plurality of high frequency impact absorbing elements; a pair of adjustment pieces partially embedded or adhered to the low portion of the base body; and an adjustment band or strap that joins both adjustment pieces; wherein the base body is made of a material capable of absorbing low frequency impacts and the plurality of high frequency impact absorbing elements are made of a material capable of absorbing high frequency impacts. The present invention further relates to a method for producing a new headgear.

Claims

1. A headgear for protecting the head of a person, the headgear comprising: a base body; a plurality of high frequency impact absorbing elements embedded in or adhered to the base body; a cover element that surrounds the base body and the plurality of high frequency impact absorbing elements as well as comprises a fabric made of different materials with a specific pattern; a pair of adjustment elements partially embedded in or adhered to the low portion of the base body; and an adjustment band or strap that joins both adjustment pieces; wherein the base body is made of a material capable of absorbing low frequency impacts and the plurality of high frequency impact absorbing elements are made of a material capable of absorbing high frequency impacts; wherein the headgear further comprises a sweat absorbing element placed in the inner forehead of the headgear.

2. The headgear of claim 1, wherein the base body comprises a hollow portion for introducing the head of a user.

3. The headgear of claim 1, wherein a front part of the base body can be open face, full face (face saver) or have cheek protection.

4. The headgear of claim 1, wherein the base body is designed from anthropometric measures.

5. The headgear of claim 4, wherein the anthropometric measures are obtained by database with a three-dimensional model of a head according to the headgear size.

6. The headgear of claim 3, wherein an opening of the front part of the base body having an open face provides a lateral field of view of 230° and an upward field of view of 53°.

7. (canceled)

8. (canceled)

9. (canceled)

10. The headgear of claim 1, wherein the adjustment pieces further comprise a plurality of holes that distribute the shear forces in the material of the base body.

11. The headgear of claim 10, wherein the plurality of holes of the adjustment elements are located at the portion that is inserted into the base body.

12. The headgear of claim 1, wherein the adjustment band comprises a band with a hook and loop fastener

13. (canceled)

14. (canceled)

15. The headgear of claim 1, wherein the base body further comprise a plurality of cavities for housing the plurality of high frequency impact absorbing elements.

16. The headgear of claim 15, wherein each one of the plurality of high frequency impact absorbing elements is shaped to match a corresponding one of the plurality of cavities of the base body.

17. (canceled)

18. (canceled)

19. The headgear of claim 1, wherein the material capable of absorbing high frequency impacts is a D30, Koroyd®, Purple®, Poron® XRD®, Antrilage®, NBR, PVC, or Vinyl Nitrile, material.

20. The headgear of claim 1, wherein the plurality of high frequency impact absorbing elements comprises a back protector, a forehead protector, two lateral protectors that protects the ears, two jaw protectors, two nape protectors, two parietal protectors and two temple protectors

21. The headgear of claim 1, wherein the material capable of absorbing low frequency impacts is Ethylene and Vinyl Acetate/V2 (EVA compound with V2 shock absorbing blend), wherein the proportion of E and VA compounds is between 15% to 35% of VA; and between 85% to 65% of E.

22. The headgear of claim 1, wherein the material capable of absorbing low frequency impacts may present at least one of the following features: hypoallergenic, antimicrobial, antibacterial, UV rays resistant, scented and/or a material that prevents fungal formation

23. The headgear of claim 22, wherein the base body and the lateral protectors on each side of the head are configured to provide a system that allows air to escape from the ear.

24. The headgear of claim 23, wherein the system that allows air to escape comprises of two holes that pass through both the base body and the respective lateral protector.

25. The headgear of claim 24, wherein the holes may be placed in different planes.

26. (canceled)

27. A method for manufacturing a headgear, comprising the steps of: molding the base body with an EVA compound which has the following proportion of Vinyl Acetate (VA) and Ethylene (E); between 15% to 35% of VA between 85% to 65% of E; V2 shock absorbing compound, once molded the base body with this blend the base body will has a hardness of 40-50 asker C manufacturing, by molding, a base body, wherein a pair of adjustment elements are placed during or after the molding process; providing a plurality of high frequency impact absorbing elements; placing each one of the plurality of high frequency impact absorbing elements into a corresponding cavity or smooth surface of the base body; providing a cover element: placing a cover element over the base body and the plurality of high frequency impact absorbing elements; providing an adjustment band or strap; and passing the adjustment band or strap through a plurality of grooves of the adjustment elements.

28. (canceled)

29. (canceled)

30. (canceled)

31. (canceled)

32. (canceled)

33. (canceled)

34. (canceled)

35. (canceled)

36. (canceled)

37. (canceled)

38. (canceled)

39. (canceled)

40. (canceled)

41. (canceled)

42. The headgear of claim 1, wherein the material capable of absorbing high frequency impacts is a material configured for attenuating high frequency impacts by reducing damping.

43. (canceled)

Description

BRIEF DESCRIPTION OF THE FIGURES

[0036] FIG. 1 shows a boxer's punch applying a force to a head form.

[0037] FIG. 2 is a graphic showing the probability of an injury against HIC score.

[0038] FIG. 3 is a graphic showing the HIC-Fatality showing AIS.

[0039] FIG. 4 is a graphic showing the Head acceleration result peak for different headgears obtained by laboratory tests.

[0040] FIG. 5 is a graphic showing the Head Injury Criterion for different headgears obtained by laboratory tests.

[0041] FIGS. 6A-6C are showing the HIC resultant points at 2 m/s, 3 m/s and 4 m/s for different headgears obtained by laboratory tests.

[0042] FIG. 7 shows a front view of the headgear of the present invention.

[0043] FIG. 8 shows an upper perspective view of the headgear of the present invention.

[0044] FIG. 9 shows an exploded front view of the headgear of the present invention.

[0045] FIG. 10 shows an exploded perspective view of the headgear of the present invention.

[0046] FIG. 11 shows a perspective view of a back protector of the new headgear of the present invention.

[0047] FIG. 12 shows a perspective view of a forehead protector of the new headgear of the present invention.

[0048] FIG. 13 shows a perspective view of a lateral protector of the new headgear of the present invention.

[0049] FIG. 14 shows a perspective view of a jaw protector. of the new headgear of the present invention.

[0050] FIG. 15 shows a perspective view of a nape protector of the new headgear of the present invention.

[0051] FIG. 16 shows a perspective view of a parietal protector of the new headgear of the present invention.

[0052] FIG. 17 shows a perspective view of a temple protector of the new headgear of the present invention.

[0053] FIG. 18 shows a perspective view of a side protector (jaw protector and lateral protector combination) of the new headgear of the present invention.

[0054] Other advantages and features will be apparent from the following description and the claims.

DESCRIPTION OF THE INVENTION

[0055] The present invention relates to a headgear comprising a base body, a plurality of high frequency impact absorbing elements embedded or attached to the base body, a cover element that surrounds the base body and the plurality of high frequency impact absorbing elements, a pair of adjustment pieces partially embedded or adhered to the low portion of the base body and an adjustment band or strap that joins both adjustment pieces; wherein the base body is made of a material capable of absorbing low frequency impacts such as (EVA) Ethilene Vynil Acetate, (EVA/V2), (PE/EVA). and the plurality of high frequency impact absorbing elements are made of a material capable of absorbing high frequency impacts such as. (D3O, Koroyd®, Purple®, Poron® XRD®, Artilage®, NBR, VN, PVC).

[0056] The term “high frequency” shall be understood as the presence of a low-rise time which results a higher settling time due to a large overshoot. The term “low frequency” shall be understood as the presence of a high-rise time which results a lower settling time is in a shorter period.

[0057] The preferred embodiment of the invention is illustrated in the drawings as shown by the FIGS. 6-18. The present invention comprises a headgear indicated by the numeral 100, the headgear comprises a base body or main body 110 comprising a hollow portion for introducing the head of a user. The front part of the base body 110 is open in such a way that the eyes, nose and mouth of the user are not covered by the base body 110 (open face), the base body 110 can also cover the cheek area offering cheek protection (Mexican style), furthermore the base body 110 can have a rigid bar going across the face protecting the nose offering full face coverage (face saver).

[0058] The base body 110 is designed from anthropometric measurements based on SLIMDESIGN® company database, providing a set of three-dimensional models of different sizes of a head, which results in an ergonomic design that perfectly fits to a higher percentage of the users.

[0059] During a battle, the fighter's vision is very important in terms of defense. It is a human factor concept that visibility access may increase user performance in the discipline. Having a full visual function and thus able to see your surroundings can help avoid injuries. A study carried by Deering Michael F. entitled “The Limits of Human Vision” determined that the Human Eye vision is of 220° for the lateral field of view (−59° to +110° for each eye) and 56° for the upward field of view (−70° to +56° vertically). The opening of the base body 110 of the present invention (open face) reaches higher values, allowing the fighters a normal vision range. The opening reaches the values of 230° for the lateral field of view and 53° for the upward field of view.

[0060] The base body 110 is made of a material capable of absorbing low frequency impacts. In one embodiment of the invention, the material capable of absorbing low frequency impacts is Ethylene and Vinyl Acetate/V2 (EVA compound with V2 shock absorbing blend). Compound specially developed to improve the impact absorption of the base body 110, however, other materials that attenuate low frequency impacts can be used to manufacture the base body 110 (Cross-Linked Polyethylene/EVA, PE/EVA, EVA) These materials absorb less impact and resist less abrasion and tear.

[0061] The material capable of absorbing low frequency impacts may present at least one of the following features: being a hypoallergenic, antibacterial, antimicrobial, UV rays resistant, scented and/or a material that prevents fungal formation.

[0062] In the preferred embodiment of the invention, the base body 110 comprises a plurality of openings that provide an adequate ventilation. In an alternative embodiment of the invention, there is an opening at the upper part of the base body 110, which provides a hair exit allowing long hair users comfort and better headgear fit and performance while using the headgear.

[0063] In a preferred embodiment of the invention, the base body 110 comprises a plurality of cavities for housing a plurality of high frequency impact absorbing elements 120. The plurality of high frequency impact absorbing elements 120 are made of a material capable of absorbing high frequency impacts. The plurality of high frequency impact absorbing elements 120 are configured to dissipate and absorb energy produced by an impact and attenuating the variations of the accelerations produced by an impact, which reduce the damage caused by the impact.

[0064] In one embodiment, the material capable of absorbing high frequency impacts may be made from one selected of the following materials: D30, Koroyd®, Purple®, Poron® XRD®, Artilage®, NBR, VN, PVC. It is important to mention that the material capable of absorbing high frequency impacts is not limited to the above-mentioned material and other kind of materials which absorb high frequency impacts may be used.

[0065] The plurality of high frequency impact absorbing elements 120 are placed in specifics position of the base body to protect specific zones of the head. Specifically, the plurality of high frequency impact absorbing elements 120 comprises a back protector 121, a forehead protector 122, two lateral protectors 123 that protects the ears, two jaw protectors 124, two nape protectors 125, two parietal protectors 126 and two temple protectors 127. Likewise, each one of the plurality of high frequency impact absorbing elements 120; may be obtained by, i.e., die cutting a plate of a material capable of absorbing high frequency impacts; however, the plurality of high frequency impact absorbing elements may be obtained by other cutting methods are configured to match the cavities of the base body 110.

[0066] In the portions of the base body 110 that covers the ears are configured to receive the lateral protectors 123. Both the base body 110 and the lateral protectors 123 on each side of the head are configured to provide a system that allow air to escape from the ear if the side of the head is struck, preventing additional damage to the eardrum due to trapped air. In one embodiment of the invention, the system that allow air to escape comprises two holes that pass through both the base body 110 and the respective lateral protector 123. Additionally, the holes may be placed in different planes.

[0067] In an additional embodiment of the invention, the system that allow air to escape may further comprise protruded EVA pieces on the base body that decrease the probability of trapping the air between the ear and the headgear.

[0068] At each side of the base body 110, there are two adjustment elements 140 that are adhered or partially inserted in the lowest portion of the base body, more specifically, the adjustment elements 140 are partially inserted or adhered in the lower jaw zone. The adjustment elements 140 may be two plastic plates that comprises a plurality of holes that distribute the shear forces in the material of the base body 110. The plurality of holes of the adjustment elements 140 are located at the portion that is inserted into the base body 110. The adjustment elements 140 are designed to resist the forces exerted by a person in order to prevent the adjustment elements from breaking. The adjustment elements 140 may be made from a thermoplastic elastomer.

[0069] The portions of the adjustment elements 140 that are not inserted or adhered to the base body 110, comprise at least one groove through which can pass an adjustment band or strap to loosen or tighten the headgear 100. In a preferred embodiment of the invention, the adjustment band may be a band with a hook and loop fastener; however, other kind of elements may be used for the adjustment of the headgear.

[0070] Both the base body 110 and the plurality of high frequency impact absorbing elements 120 are enclosed by a cover element 130. In a preferred embodiment of the invention, the cover element comprises a fabric made of spandex with a specific pattern, which provides an elegant look. It should be understood that different materials may be employed for the cover element i.e. plastic covers, paint, leather, synthetic leather, etc.

[0071] As an alternative embodiment of the invention, the headgear may further comprise an absorbing element placed in the inner forehead of the headgear which absorbs the sweat. In an exemplary but not limitative embodiment, the absorbing element may be made of rayon/polypropylene or viscose/polyester.

[0072] Due to the combination of the foregoing features, the headgear of the present invention is able to reduce the thickness and the weight of the headgear, without compromising its performance for absorbing low frequency impacts and high frequency impacts due to the combination of the material capable of absorbing high frequency impacts and the material capable of absorbing low frequency impacts, reducing by this way the probability of suffering severe head and brain injuries.

[0073] In order to manufacture the headgear 100 of the present invention, the following method is performed:

[0074] molding the base body with an EVA compound which has the following proportion of Vinyl Acetate (VA) and Ethylene € [0075] A. between 15% to 35% of VA [0076] B. between 85% to 65% of E [0077] V2 (elastomeric polymer property of Vulcan Pro Tech previously mentioned) shock absorbing compound.

[0078] In some cases, once molded the base body 110 can have a hardness of 40-50 asker C. In some cases, once molded the base body 110 can have a hardness of 40-65 asker C. Once molded the base body 110 can have a hardness of 40-50 asker C, 40-55 asker C, 45-55 asker C, 40-60 asker C, 40-65 asker C, 50-60 asker C, 50-65 asker C, or 55-65 asker C. Once molded the base body 110, will has a hardness of 40-50 asker C, being capable of absorbing low frequency impacts in order to form a base body 110, while molding, the material capable of absorbing low frequency impacts, a pair of adjustment elements 140 is placed into the base body 110 in the portion that will protect the lower jaw of the user, in such a way that the adjustment elements 140 partially protrude from the base body 110;

[0079] providing a pair of adjustment elements 140;

[0080] providing a plurality of high frequency impact absorbing elements 120; placing each one of the pluralities of high frequency impact absorbing elements 120 into a corresponding cavity or smooth surface of the base body 110;

[0081] providing a cover element 130; placing a cover element 130 over the base body 110 to cover the base body 110 and the plurality of high frequency impact absorbing elements 120;

[0082] providing an adjustment band or strap; pass the adjustment band or strap through a plurality of grooves of the adjustment elements 140;

[0083] packaging the headgear 100.

[0084] In a preferred embodiment of the method, the base body 110 may be placed on a mannequin and an adhesive is applied to the outer surface of the base body 110.

[0085] In a preferred embodiment of the method, the step of providing the plurality of high frequency impact absorbing elements 120 comprises:

[0086] providing a plate of a material capable of absorbing high frequency impacts; applying an adhesive over the both sides of the plate;

[0087] covering both sides of the plate with a nonstick material; and

[0088] die cutting the plurality of high frequency impact absorbing elements 120; wherein the shape of the high frequency impact absorbing elements 120 corresponds to the shape of the cavities formed in the base body 110.

[0089] The step of placing each one of the plurality of high frequency impact absorbing elements 120 into a corresponding cavity or smooth surface of the base body 110 further comprises removing the nonstick material from one side of one of the high frequency impact absorbing elements 120; applying an activating solvent on the one side of the high frequency impact absorbing element 120; and placing the high frequency impact absorbing element 120 into a corresponding cavity or smooth surface of the base body 110.

[0090] In a preferred embodiment of the method, wherein the high frequency impact absorbing elements may have any shape and be adhered to a smooth base body 110. Placing this shape in a smooth surface of the base body 110 further comprises removing the nonstick material from one side of one of the high frequency impact absorbing elements 120; applying an activating solvent on the one side of the high frequency impact absorbing element 120; and placing the high frequency impact absorbing element 120 into a smooth surface of the base body 110.

[0091] In a preferred embodiment of the method, the step of providing a cover element 130, further comprises: providing a plate of thermoformable material laminated or not laminated with a cover material; cutting the plate of a thermoformable material laminated or not laminated with a cover material according to the measurements of the headgear; placing decals by heat transfer over the surface of the cover material; placing the plate of a thermoformable material laminated or not laminated with a cover material on a thermoforming machine; heating the surface of the plate of a thermoformable material laminated or not laminated with a cover material; thermoforming the plate of thermoformable material laminated or not laminated with a cover material by placing the plate of thermoformable material laminated or not laminated with a cover material on a male mold; generating a vacuum or compressing the plate of a thermoformable material laminated or not laminated with a cover material so the plate of a thermoformable material laminated or not laminated with a cover material take the shape of the male mold; cooling the plate of a thermoformable material laminated or not laminated with a cover material; removing the excess of material; and applying an adhesive to the inner of the thermoformed plate of a thermoformable material laminated or not laminated with a cover material.

[0092] In a preferred embodiment of the method, the step of placing a cover element 130 over the base body 110 to cover the base body 110 and the plurality of high frequency impact absorbing elements 120 further comprises: applying an activating solvent over the external surface of the base body 110; and sticking the cover element 130 over the headgear 100.

[0093] In a preferred embodiment of the invention, the step of providing a pair of adjustment elements 140 further comprises: manufacturing the adjustment elements by injection.

[0094] In a preferred embodiment of the invention, the step of packaging the headgear 100 further comprises: placing instructions on the adjustment elements 140; wherein the instructions contain indications for placing the adjustment band into the adjustment elements 140 and wherein the instructions are attached to the adjustment elements using a plastic arrow.

[0095] Alternatively, the instructions may contain information regarding the improvements of the headgear.

[0096] The step of packaging the headgear may further comprise packaging the headgear into a bag; introducing the bag into a box and sealing the box; wherein the bag may be a bag with the shape of a head.

[0097] The molding process used during the method for manufacturing described in the present application, encompasses any of the following molding process:

[0098] Powder metallurgy plus sintering

[0099] Compression molding

[0100] Extrusion molding

[0101] Injection molding

[0102] Laminating

[0103] Reaction injection molding

[0104] Matrix molding

[0105] 15

[0106] Rotational molding (or Rotomolding)

[0107] Spin casting

[0108] Transfer molding

[0109] Thermoforming

[0110] Vacuum forming.

[0111] The present invention will be illustrated by the following examples in detail. The examples of the present invention are merely intended to describe the technical solution of the present invention, and should not be considered as limiting the spirit and scope of the present invention.

Impact Test:

[0112] In order to achieve the claimed technical features of the invention, the present invention presents a new headgear comprising a base body, a plurality of high frequency impact absorbing elements embedded in or adhered to the base body, a cover element that surrounds the base body and the plurality of high frequency impact absorbing elements; a pair of adjustment pieces adhered or partially embedded in the low portion of the base body and an adjustment band or strap that joins both adjustment pieces; wherein the base body is made of a material capable of absorbing low frequency impacts and the plurality of high frequency impact absorbing elements are made of a material capable of absorbing high frequency impacts.

Methodology

[0113] Custom R&D Contract testing to the general requirements of ASTM F1446-201 Sb “Standard Test Methods for Equipment and Procedures Used in Evaluation the Performance Characteristics of Protective” per Vulcan Pro Tech's Test Methodology/per Moon Projects Test Methodology and ASTM F2397-2009 (Reapproved 2015) “Protective Headgear Used on Martial Arts per Vulcan Pro Tech's specifications/per Moon Projects specifications.

Procedures:

[0114] Testing protocols were made by the/CS Laboratories Ine. in line with good laboratory practice were employed unless otherwise specified, for all tests.

[0115] Testing requirements as specified within Section 12 of ASTM F1446-2015b and ASTM F2397-2009 were followed.

[0116] Samples were stored for a minimum period of 24 hours at constant temperature 17° C. to 27° C. and a relative humidity of 20% to 80%.

Equipment:

[0117] Twin Wire apparatus was used to perform all impacts, Cadex CCS system was employed for data acquisition, K1 A Magnesium Headforms[s}˜]1” MEP calibration pad was employed for system checks Cadex Impact Software V6.9U.

[0118] Laboratory test were done to compare the different headgear in the market. As shown in TABLE 5 and TABLE 6, only NEW HEADGEAR fulfills the normative requirements, and surprisingly reduces the risk of minor brain injury 5 times as much vs MACHO SPARTEC® and even more surprisingly more than 10 times vs COMMON HEADGEAR® in 3 m/s. The minor brain injury risk is reduced by half as compared to all the other headgears in 4 mis, the major brain injury risk is reduced 20 times vs COMMON HEADGEAR® and major brain injury risk reduces 16 times vs MACHO SPARTEC®, the critical brain injury risk is reduced from 65% with a COMMON HEADGEAR® to a null percentage with NEW HEADGEAR and critical brain injury risk is reduced from 12.5% with MACHO SPARTEC® to a null percentage with NEW HEADGEAR Fatal brain injury risk is reduced from 25% with COMMON HEADGEAR® to a null percentage with New Headgear.

TABLE-US-00005 TABLE 5 Minor Major Peak Brain Brain Acceleration Acceleration Injury Injury BRAND & MODEL at 3 m/s [g] Absorption HIC HIC Absorption Risk Risk COMMON 270.4 70.13% 492 68.92% 80.00% 15.00% HEADGEAR.sup. ® MACHO 114.6 87.34% 268 83.07% 37.50%  5.00% SPARTEC.sup. ® GAME 317.4 64.94% 729 53.95% 95.00% 30.00% BREAKER.sup. ® WINNING.sup. ® 110.8 87.76% 236 85.09% 27.50%  3.00% VULCAN  55.9 93.82% 116 92.67%  7.50%  0.00% VICTORY.sup. ®

TABLE-US-00006 TABLE 6 Minor Major Critical Fatal Peak Brain Brain Brain Brain BRAND & Acceleration Acceleration HIC Injury Injury Injury Injury MODEL at 4 m/s [g] Absorption HIC Absorption Risk Risk Risk Risk COMMON 930.1 19.57% 2254 47.36% 100.00% 100.00% 65.00% 25.00% HEADGEAR.sup. ® MACHO 325.4 71.86% 1364 68.15% 100.00%  82.50% 12.50%  0.00% SPARTEC.sup. ® WINNING.sup. ® 314.1 72.84% 1051 75.46% 100.00%  60.00%  5.00%  0.00% VULCAN 100.5 91.31%  318 92.57%  50.00%  5.00%  0.00%  0.00% VICTORY.sup. ®

[0119] The TABLES 5 & 6 show the results obtained for 3 m/s and 4 m/s in the free fall impact test, in these results it is possible to see that new Headgear incredibly reduces the damage taken due to the construction of the headgear: The high frequency impact absorbing elements 120; of the outside material reduces the impact until it gets in the low impact attenuation range of the inside material element 110, achieving as a result the best attenuation, and maintaining the same level of attenuation no matter the impact energy (FIGS. 5-6).

[0120] The devices and method discussed herein are merely illustrative of specific manners in which to make and use this invention and are not to be interpreted as limiting in scope.

[0121] While the devices and method of the invention have been described with a certain degree of particularity, it is to be noted that many modifications may be in the details of the construction and the arrangement of the devices and components without departing from the spirit and scope of this disclosure. It is understood that the devices and methods are not limited to the embodiments set forth herein for purposes of exemplification.