Protective headgear

Abstract

Protective headgear in one case comprises a main body having a pair of side head parts connected by a forehead part and a crown part extending from the forehead part. The body is shaped to encompass the head of a wearer. The main body comprises an inner sheet of an open cell polyurethane foam material, an outer barrier layer, and an intermediate section comprising portions of an open cell polyurethane foam material between the inner and the outer layers. The open cell polyurethane foam has a density of from 100 to 300 kg/m.sup.3 which significantly reduces the G-force energy transferred to a players head during impact.

Claims

1. A protective headgear comprising a main body comprising: a pair of side head parts connected by a forehead part and a crown part extending from the forehead part, the main body being configured to encompass the head of a wearer; an inner layer of wicking material; an outer barrier layer; and an intermediate section between said inner layer of wicking material and said outer barrier layer, the intermediate section comprising: an inner foam layer; and an outer foam layer comprising a plurality of spaced-apart foam pieces, wherein said inner foam layer and said outer foam layer of the intermediate section comprise an impact resistant open cell polyurethane foam having a density of from 100 to 300 kg/m.sup.3, and wherein the outer barrier layer comprises a plurality of pockets which are configured to receive the foam pieces of said intermediate section outer foam layer.

2. The protective headgear as claimed in claim 1 wherein the intermediate section comprises an impact resistant open cell polyurethane foam having a density of from 150 to 250 kg/m.sup.3.

3. The protective headgear as claimed in claim 1 wherein the intermediate section inner foam layer is of an impact resistant open cell polyurethane foam having a density of from 150 to 250 kg/m.sup.3.

4. The protective headgear as claimed in claim 1 wherein the intermediate section inner foam layer has a first thickness and the intermediate section outer foam layer has a second thickness which is greater than the first thickness.

5. The protective headgear as claimed in claim 4 wherein the second thickness is from 1.5 to 5 times the first thickness.

6. The protective headgear as claimed in claim 4, wherein the second thickness is from 1.5 to 3 times the first thickness.

7. The protective headgear as claimed in claim 4, wherein the second thickness is about 2 times the first thickness.

8. The protective headgear as claimed in claim 4, wherein the intermediate section inner foam layer is about 3 mm in thickness and the intermediate section outer foam layer foam pieces are about 6 mm in thickness.

9. The protective headgear as claimed in claim 1 wherein the intermediate section inner foam layer is perforated.

10. The protective headgear as claimed in claim 9 wherein the intermediate section inner foam layer comprises from 3 to 5 holes per cm.sup.2 and the holes are from 2 mm to 4 mm in diameter.

11. The protective headgear as claimed in claim 1 wherein the intermediate section inner foam layer comprises a wicking fabric bonded to the inner layer of open cell foam.

12. The protective headgear as claimed in claim 1 wherein the outer barrier layer comprises closed cell foam.

13. The protective headgear as claimed in claim 1 wherein G-Force energy transferred to a wearer's head during impact is less than 150.

14. The protective headgear as claimed in claim 13, wherein G-Force energy transferred to the wearer's head during impact is less than 120.

15. The protective headgear as claimed in claim 1, further comprising an outer fabric bonded to the outer barrier layer.

16. The protective headgear as claimed in claim 1, wherein each side part of the main body comprises a plurality of through holes for alignment with a wearer's ears.

17. The protective headgear as claimed in claim 1, wherein each side part of the main body comprises a mounting for a chin strap.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention will be more clearly understood from the following description of an embodiment thereof, given by way of example only, with reference to the accompanying drawings, in which:

(2) FIGS. 1 to 7 are elevational views of protective headgear such as rugby headgear according to the invention;

(3) FIG. 8 is a plan view of an assembly used to form the headgear;

(4) FIG. 9 is a plan view of side parts of the headgear;

(5) FIG. 10 is an exploded view of the side parts of the headgear;

(6) FIG. 11 is a plan view of an exterior element of the side parts;

(7) FIG. 12 is a plan view of a perforated foam element of the side parts;

(8) FIG. 13 is an enlarged view of a detail of the perforated foam element of the side parts;

(9) FIG. 14 is an enlarged view of an assembly of the outer layer, open cell foam elements and the perforated foam element of the side parts;

(10) FIG. 15 is a plan view of a crown part of the headgear;

(11) FIG. 16 is an exploded view of the crown part of the headgear;

(12) FIG. 17 is a plan view of an exterior element of the crown part;

(13) FIG. 18 is a plan view of the perforated foam element of the crown part;

(14) FIG. 19 is a series of views of a chinstrap of the headgear;

(15) FIG. 20 is a view of a lace-hole reinforcement patch of the headgear;

(16) FIG. 21 is a view of a strap-reinforcement patch of the headgear;

(17) FIG. 22 is an exploded view of the crown part of rugby headgear according to the invention;

(18) FIG. 23 is a micrograph of the open cell foam used in the headgear of the invention;

(19) FIG. 24 is a bar chart of hind-leg foot-slips;

(20) FIG. 25 is a bar chart of time to cross beam;

(21) FIG. 26 is a bar chart of distance traveled;

(22) FIG. 27 is a bar chart of NEFL Levels;

(23) FIG. 28 is a bar chart of TNF- Levels;

(24) FIG. 29 is a bar chart of impact test results for drop testing;

(25) FIG. 30 is a chart of test results for Rotational Acceleration testing;

(26) FIG. 31 is a side view of protective headgear such as soccer headgear according to the invention;

(27) FIG. 32 is a plan view of protective headgear such as soccer headgear according to the invention;

(28) FIG. 33 is an elevational view of protective headgear such as boxing headgear according to the invention;

(29) FIG. 34 is a plan view of protective headgear such as boxing headgear according to the invention;

(30) FIG. 35 is an elevational view of protective headgear such as mixed martial arts headgear according to the invention; and

(31) FIG. 36 is a plan view of protective headgear such as mixed martial arts headgear according to the invention.

DETAILED DESCRIPTION

(32) We describe rugby scrum caps which have the benefit of initially appearing not dissimilar to a typical rugby scrum cap. In various embodiments, it is not significantly thicker, allows for adequate hearing and visibility, and significantly reduces a major risk factor in sports induced mTBI/concussion to the player, impacts to the head.

(33) In order to achieve the protection required to the head in order to reduce the risk of mTBI/concussion, it has been found that an increased density of the scrum cap is required. This is achieved by a combination of materials.

(34) The headgear of the invention has showed a vast improvement for impact performance on known scrum caps. The headgear of the invention reduces the incidence and/or severity of significant alterations in clinically measurable mTBI indicators (both behavioural and neurological blood biomarkers) and thereby enhances player's performance and maximises their safety. The headgear of the invention significantly reduces the G-Force of linear and rotational impacts transferred to the player's head.

(35) Referring to the drawings and initially to FIGS. 1 to 21 thereof there is illustrated protective headgear according to the invention which in one case is rugby headgear. The headgear comprises a main body 1 which encompasses a wearer's head. The main body 1 has side head parts 2, 3 connected by a forehead part 4 and a crown part 5 extending from the forehead part 4. The crown part 5 may be formed separately from the side and forehead parts and subsequently joined to the forehead part 4, for example by stitching.

(36) Each part of the main body 1 comprises a number of layers. There is an inner foam layer 10 of an open cell polyurethane foam material. The inner foam layer 10 comprises a sheet of foam which is perforated with a plurality of holes 12, preferably from about 3 to 5 holes per cm.sup.2. The holes assist in wicking away sweat generated by the wearer and are preferably from 2 to 4 mm in diameter. A wicking fabric such as Nylon wicking fabric 11 is bonded, for example using a suitable adhesive, to the wearer engaging face of the inner perforated foam sheet 10.

(37) The inner foam layer provides additional impact protection to the head protector. The perforated holes also assist in reducing the heat of the player's head by helping the sweat to be drawn away from the player's head. The perforated holes also assist in reducing the overall mass of the head protector.

(38) The main body 1 also comprises an outer barrier layer 13 which in this case is of a closed cell foam material such as a polyethylene foam. The outer barrier layer 13 is formed to provide a plurality of outwardly facing pockets 14. An outer fabric 15 such as a stretch Nylon is bonded to the external face of the barrier foam layer 13 in a suitable manner, for example using a hot melt adhesive. The headgear has a soft rather than a hard shell.

(39) The barrier layer 13 is moulded to form the pockets 14 that hold intermediate foam pieces 21 in place. The outer barrier layer 13 can be made from a closed cell polyethylene foam that is waterproof to prevent excess rain and moisture from entering the head protector, in use. This ensures that the mass of the head protector does not increase in wet conditions and remains comfortable for a player.

(40) An intermediate section 20 of an open cell polyurethane foam material is provided between the outer barrier layer 13 and the inner layer. In this case, the intermediate foam section 20 comprises a plurality of portions/pieces 21 which are sized to engage in the pockets 14 of the outer barrier/layer 13.

(41) The open cell foam of both the internal foam layer and the intermediate foam section is an impact resistant polyurethane foam which consists of a branched polyether-based polyol and a chain extender. The foam has a density in the range of from 100 to 300 kg/m.sup.3, preferably from 150 to 250 kg/m.sup.3, most preferably about 190 kg/m.sup.2. Such foams are available from suppliers including Dow Automotive, Dow Corning, Rogers Corporation, Sorbothane Inc., and DuPont.

(42) The intermediate foam section 20 provides the majority of the impact protection of the product. The foam has a relatively low density which ensures that the head protector is lightweight. The foam is soft to touch which makes it comfortable to wear on the head. The softness of the foam also facilitates profiling to the contours of the head during manufacturing. Unlike crushable foams that are commonly used in sports helmets the foam 20 is able to recover from multiple impacts, to give impact protection throughout a game. Studies have shown that the average number of impacts to the head in a game of rugby is 77.

(43) The headgear of the invention dissipates the impact energy through the cellular microstructure of the open cell foam used in the construction of the headgear. The open cell foam may have hard and soft segments. The soft segments absorb and dissipate the energy of the impact. The hard segments provide rigidity, shape and form to the foam. A typical micrograph of the open cell foam is illustrated in FIG. 23.

(44) The inner open cell perforated foam sheet 10 has a first thickness and the intermediate open cell foam section pieces 21 have a second thickness which is greater than the first thickness, in the order of 1.5 to 5 times, preferably from 1.5 to 3, typically about 2 times greater in order to minimise the weight of the head protector. In one case the perforated foam sheet 10 is 3 mm in thickness and the foam section pieces 21 are 6 mm in thickness.

(45) The side head parts 2, 3 have a plurality of through holes 30 for alignment with a wearers ears to ensure that the headgear does not interfere with the wearer's hearing. Each side part 2, 3 also comprises a slot 35 for mounting a chin strap 40 to the headgear. In the invention, the chinstrap is replaceable. The advantage is that if the stickiness of the Velcro declines due to wear and tear in use, the chinstrap may be replaced without having to replace the head protector. There are also reinforcement pieces 36 for re-enforcing the headgear in the region of the chin strap holes 35. Each of the side parts 2, 3 also has a lace hole reinforcement part 39 at a side edge thereof, through which a lace 45 is led as shown, for example in FIG. 7. The lace 45 allows the size of the headgear to be adjusted to suit a wearer.

(46) To manufacture protective headgear according to the invention an outer fabric layer is laminated to a sheet of polyethylene foam which is used to form the outer barrier layer 13. The laminate is then moulded to provide a plurality of pockets 14. The laminate is die cut to provide the crown 5 and side parts 2, 3 and forehead 4 shapes. The side parts 2, 3 and the forehead 4 parts are all formed as a single piece that wraps from your ear, around the forehead, to the other ear.

(47) A sheet of the closed cell polyurethane foam is then cut-out into pieces 21 which are shaped to conform to the pockets 21 formed in the barrier layer 13. The intermediate foam pieces 21 are inserted and bonded, for example, using an adhesive, into the pockets 21. The crown 5 and side parts 2,3,5 are then assembled together, for example by stitching. The strap 40 and laces 45 are attached to complete the protective headgear.

(48) Referring to FIG. 22 there is illustrated an exploded view of the crown part of protective headgear of the invention. This is similar to FIG. 16 and like parts are assigned the same reference numerals. The outer fabric layer 15 is included. The innermost liner is illustrated in two components 11a, 11b and combines hydrophilic and hydropholic sections to enable rapid absorption and quick release of moisture, for example, up to 40 times its own weight. The liner 11 may also incorporate an antibacterial agent for improved hygiene properties.

(49) The headgear of the invention reduces the incidence and/or severity of concussion and thereby enhances player's performance and maximises their safety.

(50) Players using the protective headgear will have improved long term health. The adverse effects of repeated impacts to the head are well known. Further, players will miss fewer games as concussion is the most common rugby injury sustained in matches

(51) The protective headgear of the invention significantly reduces the G-Force of linear and rotational impacts transferred to the player's head.

(52) Laboratory testing has showed a vast improvement for impact performance on known scrum caps.

(53) A pre-clinical animal study has also been completed. The data has demonstrated significant reductions of TBI (Traumatic Brain Injury) indicators (behavioural and biomarkers) in a neurological rodent model.

(54) Pre-Clinical Animal Study

(55) A pre-clinical animal study was carried out to validate the performance of the protective headgear of the invention in reducing the incidence of concussion.

(56) The protective headgear of the invention was used to protect rodent test subject skulls while subjected to a controlled impact. The study asked two questions: 1. Did the behaviour of the rodents, protected with the head protector, dramatically change after a controlled impact to the head? 2. Did the blood bio-markers, which are indicative of mTBI, of the rodents protected with the protective headgear, dramatically change after a controlled impact to the head?

(57) The objective of the study was to illustrate proof of concept evidence in a pre-clinical setting with a well validated TBI animal model. The model selected used a controlled impact mechanism, analogous to an impact received in the field of play, a well-characterized concussion pathophysiology and definitive clinical indicators that has close fidelity to concussion in humans Recent publications have used this pre-clinical model and have established a correlation between TBI and clinical read-outs of pathology occurring within the brain such as blood biomarkers and altered gene expression profiles. Viano, D., A. Hamberger, A. Bolouri, and A. Saljo, Concussion in professional football: Animal model of brain injuryPart 15, Neurosurgery, 2009, 64, 1162-1173. Mychasiuk, R., Hehar, H., Ma, I., Candy, S., & Esser, M J. (2016). The direction of the acceleration and rotational forces associates with mild traumatic brain injury in rodents effect behavioural and molecular outcomes. Journal of Neuroscience Methods. 257, 168-178.

(58) 1. Behavioural Analysis Results

(59) The protective headgear of the invention protected rats from concussions resulting from head impact occurring at 5 m/s (37 g). The protective effects were evident in the behavioural measures examining balance, motor coordination, and exploratory locomotion.

(60) (a) Hind-Leg Foot-Slips

(61) Animals in the group that were protected with the protective headgear of the invention did not exhibit impairment in the number of foot-slips or time to cross a beam whereas both of these deficits were present in the non-protected group. See FIG. 24.

(62) (b) Time to Cross Beam

(63) Animals that had the protective headgear of the invention were indistinguishable from control animals regardless of the impact force, whereas animals without the protective headgear exhibited significant impairment (*p<0.05). See FIG. 25.

(64) (c) Distance Traveled

(65) Similar to hind-leg foot-slip findings, animals that experienced an impact at 37 g but were protected with the protective headgear of the invention were indistinguishable from control animals. However, all other animals, exhibited significant impairment in the distance traveled over the 10-minute session. See FIG. 26.

(66) The paths taken by the animals over the course of the 10-minute session were also recorded. Control animals and animals in the 37 g group with the protective headgear of the invention travel further and explore the entire enclosure whereas other animals only investigate half of the arena.

(67) 2. Blood Bio-Marker Analysis Results:

(68) The headgear of the invention protected rats from concussions resulting from head impact occurring at 5 m/s (37 g). The protective effects were evident in the biomarker levels of TNF- and NEFL at 3 hours' post-injury.

(69) (a) NEFL Levels

(70) The NEFL serum levels demonstrated significant increases in animals that did not have protection. The protective headgear of the invention prevented significant changes in NEF-L at this early time point for impacts, see FIG. 27.

(71) (b) TNF- Levels

(72) The protective headgear of the invention prevented reductions in TNF- at 3 hours' post-concussion in the 37 g impact group (*p<0.05), see FIG. 28.

(73) Linear Impact Testing

(74) Several rounds of impact drop testing were carried out to validate the performance of the protective headgear of the invention in reducing linear impact forces. The objectives of the impact drop tests were: i. Did the protective headgear of the invention reduce the linear impact force transmitted to a players' head? ii. Did the protective headgear of the invention reduce the linear impact force transmitted to a player's head better than existing rugby headguards on the market?

(75) (a) Impact Drop Test Results 1

(76) The first results of the Impact Drop Tests were that the protective headgear of the invention reduced the linear impact forces transmitted to a player's head. See FIG. 29.

(77) (b) Impact Drop Test Results 2

(78) The second results of the Impact Tests were that the protective headgear of the invention reduced the linear impact force transmitted to a player's head better than existing rugby headguards on the market. See FIG. 29.

(79) Rotational Acceleration Testing

(80) Several rounds of rotational acceleration testing were carried out to validate the performance of the protective headgear of the invention in reducing rotational impact forces when 2 players were tackling each other. The objective of the rotational acceleration tests were: 1. Did the protective headgear of the invention reduce the rotational acceleration of the headform, in a collision/tackle, when compared to players that are not wearing any head protectors?

(81) (a) Rotational Acceleration Test Results 1

(82) The results of the Rotational Acceleration Tests were that the protective headgear of the invention reduced the rotational acceleration of the headform, in a collision/tackle when compared to players that were not wearing any head protectors. See FIG. 30. i. When both head forms were protected with the protective headgear of the invention and tested at 2 m/sec the average Rotational Acceleration was reduced by 55% when compared to two unprotected head forms. ii. When both head forms were protected with the protective headgear of the invention and tested at 3 m/sec the average Rotational Acceleration was reduced by 38% when compared to two unprotected head forms. iii. When both head forms were protected with the protective headgear of the invention and tested at 4 m/sec the average Rotational Acceleration was reduced by 30% when compared to two unprotected head forms.

(83) It will be appreciated that whilst the head protector of the invention reduces the incidence of concussion in rugby it also provides the basis for protective headgear across a range of other applications including other contact sports.

(84) Referring to FIGS. 31 and 32 there is illustrated protective headgear of the invention which in this case is for use in playing soccer. The headgear comprises a main body 100 which wraps around the wearers head. The main body 100 has side head parts 102 and 103, which are connected by a forehead part 104. Each of the side parts 102, 103 also has a lace hole reinforcement part 105 at a side edge thereof, for connecting the side parts 102 and 103 to each other at the back of the head. This can be done with a lace, as described in previous embodiments, and secures the headgear to the head of the user. The construction of the various layers of the protective headgear of FIGS. 31 and 32 is the same as that described above for Rugby headgear.

(85) Soccer is the most popular sport in the world, with more than 265 million players worldwide, including professional and amateur ones. There is growing evidence that heading a football can cause both short and long-term brain damage. Studies have shown that standard soccer heading results in immediate and measurable alterations in brain function. Changes in short and long term memory function and corticomotor inhibition are detectable immediately after soccer heading. [http://www.ebiomedicine.com/article/S2352-3964(16)30490-X/abstract]

(86) The protective headgear of the invention provides a solution to this problem by providing protective headgear that will still allow the user to play soccer but which will reduce the impact from the football transferred to the head.

(87) Referring to FIGS. 33 and 34 there is illustrated the protective headgear of the invention which in this case is for use in boxing. The headgear comprises a main body 200 which encompasses the wearers head, but does not provide protection to the crown of the head as it is not required by the sport. The main body 200 has side head parts 202 and 203, which are connected by a forehead part 204. Side parts 202 and 203 are thicker than the remainder of the head gear in order to provide additional protection to the sides of the head which receive significant impacts. There is also a chin strap as in previous embodiments. Each side part 202, 203 also comprises a slot 205 for mounting a chin strap to the headgear. As in previous embodiments, the chinstrap is replaceable. Each of the side parts 202, 203 also has a lace hole reinforcement part 208 at a side edge thereof, for connecting the side parts 202 and 203 to each other at the back of the head. This can be done with a lace, as described in previous embodiments, and secures the headgear to the head of the user. Due to the nature of the sport, the headgear is further secured by a strap 206 connecting the sides 202 and 203 to each other and a further strap connecting the forehead part 204 to the back of the headgear. The construction of the various layers of the protective headgear of FIGS. 33 and 34 is the same as that described for Rugby headgear.

(88) Chronic traumatic encephalopathy (CTE) is a neurodegenerative disease, which is associated with mild repetitive traumatic brain injury (TBI). This long-term and progressive symptom due to TBI was initially called punch-drunk syndrome or dementia pugilistica, since it was believed to be associated with boxing. However, serial neuropathological studies of mild repetitive TBI in the last decade have revealed that CTE occurs not only in boxers but also in a wider population including American football players, wrestlers, and military personnel. [https://www.ncbi.nlm.nih.gov/pubmed/27395469].

(89) Conventional protective headgear in boxing has the problems that it does not reduce the rates of TBI in boxers and it can obscure peripheral vision, making it harder to see when a blow is being aimed at the side of the head.

(90) The protective headgear of the invention provides a solution to these problems by reducing the impact from a punch transferred to the head. It also offers better peripheral vision for the wearer than conventional protective headgear in boxing.

(91) Referring to FIGS. 35 and 36 there is illustrated protective headgear of the invention which in this case is used in mixed martial arts (MMA). The headgear comprises a main body 300 which encompasses a wearer's head. The main body 300 has side head parts 302, 303 connected by a forehead part 304 and a crown part 306 extending from the forehead part 304. Similarly to when used for boxing, the side parts 302 and 303 are thicker than the remainder of the head gear in order to provide additional protection to the sides of the head which receive significant impacts. Each of the side parts 302, 303 also has a lace hole reinforcement part 308 at a side edge thereof, for connecting the side parts 302 and 303 to each other at the back of the head. The construction of the various layers of the protective headgear of FIGS. 35 and 36 is the same as that described for Rugby headgear.

(92) Mixed martial arts (MMA) is a full combative sport with a recent global increase in popularity despite significant scrutiny from medical associations. Studies have shown that rates of knockouts (KOs) and technical knockouts (TKOs) in MMA, due to match-ending head trauma, are higher than previously reported rates in other combative and contact sports. [https://www.ncbi.nlm.nih.gov/pubmed/24658345]

(93) The protective headgear of the invention provides a solution to these problems by reducing the impact from a punch or kick transferred to the head. It also offers better peripheral vision for the wearer than conventional protective headgear in MMA.

(94) The invention is not limited to the embodiments hereinbefore described, which may be varied in construction and detail.