Support Structure for Headgear With Integrated Ventilation and Anchoring

Abstract

A headgear support structure for use with various types of headgear includes a rim defining a perimeter with a front edge, a rear edge, and opposing side edges; a wall extending between the edges of the rim, having an exterior surface and an interior surface; a plurality of ridges formed on the exterior surface defining grooves between them; a plurality of ventilation openings extending through the wall; and a plurality of angled pins projecting from the interior surface to engage with a wearer's hair. The structure is configured to maintain hair volume, provide ventilation for scalp health, and create a secure foundation for headgear through multi-directional friction. The support structure may be formed as a single integrated unit using additive layer manufacturing, creating a microtextured surface that enhances grip on both hair and fabrics. The structure is configurable for various headgear types including religious coverings, wigs, helmets, and fashion accessories.

Claims

1. A headgear support structure, comprising: a rim defining a perimeter of the support structure, the rim including a front edge, a rear edge, and opposing side edges; a wall extending between the edges of the rim, the wall having an exterior surface and an interior surface; a plurality of ridges formed on the exterior surface of the wall, the ridges defining a series of grooves therebetween; a plurality of ventilation openings extending through the wall from the interior surface to the exterior surface; and a plurality of pins extending from the interior surface, each pin having a pin base connected to the interior surface and angled relative to the interior surface.

2. The headgear support structure of claim 1, wherein the wall is curved in multiple planes to conform to a curvature of a wearer's head, such that the interior surface is concavely curved and the exterior surface is convexly curved.

3. The headgear support structure of claim 1, wherein the pins are arranged in a plurality of pin rows, including front-to-back pin rows extending generally from the front edge toward the rear edge and side pin rows positioned along opposing side sections of the support structure.

4. The headgear support structure of claim 3, wherein the front-to-back pin rows comprise ten rows arranged in parallel pairs, and wherein the side pin rows comprise four rows on each side of the support structure.

5. The headgear support structure of claim 1, wherein the support structure is formed as a single integrated unit using an additive layer manufacturing process.

6. The headgear support structure of claim 5, wherein the additive layer manufacturing process creates a microtextured surface in the 20-70 micron range that enhances grip on both hair and fabric.

7. The headgear support structure of claim 1, wherein the pins are angled at approximately 65 degrees relative to the interior surface.

8. The headgear support structure of claim 1, wherein the support structure is made from a material selected from the group consisting of nylon and thermoplastic polyurethane (TPU).

9. The headgear support structure of claim 1, wherein: the width of each groove between adjacent ridges is approximately 1.4 mm; the width of each ridge is approximately 1.0 mm; the height of each ridge is approximately 0.7 mm; the length of each ventilation opening is approximately 3.5 mm; the length of wall between adjacent ventilation openings is approximately 2.4 mm; the wall thickness between the interior surface and the exterior surface is approximately 0.8 mm; and the total distance from the interior surface to a peak of each ridge is approximately 1.5 mm.

10. The headgear support structure of claim 1, wherein the ridges are arranged in an arc pattern, with each ridge extending in an arc that originates at the rear edge or a rear portion of a side edge, intersects a bisecting plane of the support structure, and curves back toward the rear edge or a rear portion of the opposite side edge.

11. A support structure for use with headgear, comprising: a rim having a front edge configured to be positioned above a wearer's hairline, a rear edge, and opposing side edges; a wall extending between the edges of the rim and having an exterior surface and an interior surface; an array of ridges projecting from the exterior surface; a plurality of ventilation openings formed in the wall; and a plurality of angled pins projecting from the interior surface, each pin configured to engage with a wearer's hair to secure the support structure to the wearer's head.

12. The support structure of claim 11, wherein the front edge has an undulating profile forming concave segments at opposite sides of a bisecting plane and a convex segment that intersects the bisecting plane to form a front edge apex.

13. The support structure of claim 12, wherein the rear edge has an undulating profile with concave segments at opposite sides of the bisecting plane, a convex segment intersecting the bisecting plane to form a rear edge apex, and angular transitions that form a rearward-sweeping profile.

14. The support structure of claim 13, wherein each concave segment of the rear edge transitions through an angular transition into a rearward-sweeping segment that extends to a corresponding side edge.

15. The support structure of claim 11, wherein the support structure comprises a center section configured to extend across a mid-scalp region of the wearer's head and opposing side sections configured to be positioned proximate the wearer's ears and rearward of the wearer's temples.

16. A method of manufacturing a headgear support structure, comprising: forming, via an additive layer manufacturing process, a support structure having: a curved wall with an interior surface and an exterior surface; a plurality of ridges protruding from the exterior surface; a plurality of ventilation openings extending through the wall; and a plurality of pins extending from the interior surface at an angle of approximately 65 degrees relative to the interior surface.

17. The method of claim 16, wherein the additive layer manufacturing process comprises selective laser sintering (SLS) or Multi Jet Fusion (MJF).

18. The method of claim 16, wherein the forming step creates a microtextured surface in the 20-70 micron range.

19. The method of claim 16, wherein the headgear comprises a hijab or scarf.

20. The method of claim 16, wherein the forming step comprises forming the support structure from one of nylon and thermoplastic polyurethane (TPU).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG. 1 is a rear perspective view of a support device according to an embodiment of the present disclosure.

[0013] FIG. 2 is a front perspective view of the support device of FIG. 1.

[0014] FIG. 3 is a front elevational view of the support device of FIG. 1.

[0015] FIG. 4 is a rear elevational view of the support device of FIG. 1.

[0016] FIG. 5 is a side elevational view of the support device of FIG. 1.

[0017] FIG. 6 is another side elevational view of the support device of FIG. 1.

[0018] FIG. 7 is a top view of the support device of FIG. 1.

[0019] FIG. 8 is a bottom view of the support device of FIG. 1.

[0020] FIG. 9 is a cross-sectional view of the support device of FIG. 1 taken along the plane P1 of FIG. 8 and bisecting the support device.

[0021] FIG. 10 is an enhanced view of detail B of FIG. 9.

[0022] FIG. 11 illustrates the support device of FIG. 1 in use.

DETAILED DESCRIPTION

[0023] FIGS. 1-10 depict a headgear support structure 10 (or crown) according to an embodiment of the present disclosure. Support structure 10 is configured to be worn underneath various types of headgear to promote hair and scalp health while providing enhanced stability for the headgear. As shown, support structure 10 generally includes a rim 12, a wall 14 having an exterior surface 40 and an interior surface 42, ridges 44 formed on the exterior surface 40, grooves 46 between the ridges 44, ventilation openings 48, and pins 60 extending from the interior surface 42.

[0024] Support structure 10 is defined by rim 12 which forms a perimeter of the device. As depicted, rim 12 is continuous and helps provide structural support and the overall shape of support structure 10. However, in some examples, rim 12 may be discontinuous at various points along the perimeter of support structure 10. Such discontinuities may be strategically placed for enhanced flexibility at certain locations, for example. Rim 12 may also include flared, thinned, or flexible edge zones to reduce pressure against the scalp and improve long-term comfort during wear. These comfort features may be particularly beneficial at contact points that experience greater pressure during extended periods of use. Rim 12 includes a front edge 20, a rear edge 22, and opposing side edges 24.

[0025] Front edge 20 is configured to be positioned just above the wearer's hairline when in use. As such, front edge 20 has a curved profile configured to conform to the wearer's hairline. In this regard, support structure 10 may have a slight undulating profile extending from side-to-side. Specifically, a plane P1 (see e.g., FIG. 7) extends in a front-rear direction, intersects front edge 20, and bisects support structure 10. The undulating profile of front edge 20 forms concave curves 20a (or concave segments) disposed at opposite sides of plane P1 which merge with a convex curve 20b (or convex segment) that intersects plane P1 so as to form a front edge apex 20c, as shown in FIGS. 5 and 6.

[0026] Rear edge 22 similarly features an undulating profile forming concave curves 22a (or concave segments) at opposite sides of plane P1 and a convex curve 22b (or convex segment) intersecting plane P1 to form a rear edge apex 22c. In contrast to front edge 20, rear edge 22 further includes angular transitions 26 that forms a rearward-sweeping profile in a side view (see FIGS. 5 and 6). In other words, each concave segment 22a of rear edge 22 transitions through angular transition 26 into a rearward-sweeping segment 22d that extends from the angular transition 26 to a corresponding side edge 24. These angular transitions 26 produce an abrupt directional change in the rearward direction, as opposed to a smooth or gradual rearward curvature.

[0027] Side edges 24 extend between front edge 20 and rear edge 22 in a generally front-to-rear direction. In the illustrated embodiment, side edges 24 have a generally convex curvature. As shown in FIGS. 5 and 6, angular transitions 26 at rear edge 22 direct a rear portion 24a of side edges 24 upward to meet the rearward-sweeping segments 22d of rear edge 22. This geometry further contributes to the rearward-sweeping profile of support structure 10.

[0028] Support structure 10 can be further divided into sections based on their position relative to the wearer's head. In this regard, support structure 10 may have a center section 30 and opposing side sections 32. Center section 30 extends across the mid-scalp of the wearer's head, while opposing side sections 32 are positioned proximate the wearer's ears and rearward of the wearer's temples. Side sections 32 are at least partially defined by side edges 24 and rearward-sweeping segments 22d such that side sections 32 project more rearward than the center section 30.

[0029] Wall 14 extends between the front edge 20, rear edge 22, and side edges 24 of rim 12, and defines an exterior surface 40 and an interior surface 42 (see FIG. 10). Wall 14 has a thickness defined between exterior surface 40 and interior surface 42. In one example, the wall thickness is approximately 0.8 mm. As illustrated, wall 14 is spherically curved, such that exterior surface 40 is convexly curved and interior surface 42 is concavely curved. In this regard, wall 14 exhibits curvature in two orthogonal planes. For instance, wall 14 is curved in plane P1, as shown in the cross-section of FIG. 9, and is also curved in a plane perpendicular to plane P1, as best depicted in FIG. 3. This spherical curvature enables wall 14, and thus support structure 10, to conform to the curvature of a wearer's head.

[0030] Although wall 14 and support structure 10 are shown with spherical curvature, in other embodiments they may be flat, which may simplify manufacturing. As described below, support structure 10 may be formed from a flexible polymer material, allowing a flat configuration to bend and conform to the shape of the wearer's head during use.

[0031] Exterior surface 40 includes a plurality of ridges 44 that project outwardly to define a series of grooves 46 between adjacent ridges (see FIG. 10). In the illustrated embodiment, ridges 44 are arranged in an arc pattern, radiating in a series of curved paths. Each ridge 44 extends in an arc that originates at rear edge 22 or a rear portion 24a of a side edge 24, intersects the bisecting plane 16, and then curves back toward rear edge 22 or the rear portion 24a of the opposite side edge 24, as best shown in FIGS. 2, 5, and 6. This arrangement of ridges 44 forms a grip surface 84 that provides frictional resistance to inhibit slippage of overlying headgear during use. Additionally, the arc-shaped configuration of ridges 44 imparts multi-directional frictional characteristics, thereby reducing the likelihood of headgear slipping in any direction relative to support structure 10.

[0032] In one example, the distance between adjacent ridges 44 (i.e., the width of each groove 46) is approximately 1.4 mm. Each ridge 44 has a width of approximately 1.0 mm and a height of approximately 0.7 mm. Accordingly, the total distance from interior surface 42 of wall 14 to the peak of each ridge 44 is approximately 1.5 mm. This specific ridge configuration is configured to optimize both the frictional interface and the flexibility of support structure 10, while maintaining wearer comfort.

[0033] While the arc pattern of ridges 44 described above provides enhanced multi-directional friction, in alternative embodiments, ridges 44 may be arranged in different patterns to achieve varied functional or aesthetic objectives. For example, in one embodiment, ridges 44 may be oriented linearly in a parallel configuration extending in a front-rear direction across exterior surface 40. In another embodiment, ridges 44 may be arranged in a concentric pattern centered about a point on support structure 10, such as the apex 20c of front edge 20 or the apex 22c of rear edge 22, to create a radial grip effect.

[0034] In yet another embodiment, ridges 44 may be arranged in an intersecting grid pattern, forming a network of raised intersections that provide omni-directional friction and increased surface texture. Alternatively, ridges 44 may follow a wave-like or sinusoidal pattern that undulates across exterior surface 40, which may increase surface flexibility and dynamic grip properties. The arrangement, spacing, and shape of ridges 44 may also be varied across different regions of support structure 10 to provide zone-specific grip or structural characteristics.

[0035] Additionally, in some embodiments, ridges 44 may be discontinuous, forming segmented or interrupted patterns that provide selective frictional zones. The ridge geometry may also be modified. For example, the cross-sectional shape of each ridge 44 may be rounded, triangular, trapezoidal, or otherwise contoured to optimize friction, compressibility, or comfort based on the intended application or overlying headgear configuration.

[0036] Within the grooves 46 formed between ridges 44 are a series of ventilation openings 48. These openings 48 extend completely through wall 14, from interior surface 42 to exterior surface 40. Ventilation openings 48 collectively form a ventilation system configured to promote airflow to the wearer's scalp, thereby reducing moisture accumulation and improving comfort during extended wear of headgear. In the illustrated embodiment, the ventilation openings 48 are rectangular in shape. In one example, each ventilation opening 48 has a length of approximately 3.5 mm, and each wall segment between adjacent openings may have a length of approximately 2.4 mm.

[0037] In alternative embodiments, the ventilation openings 48 may have other shapes and arrangements. For example, openings 48 may be circular, oval, hexagonal, or slot-shaped, depending on desired airflow characteristics and manufacturing considerations. Openings 48 may also vary in size or density across different regions of support structure 10 to provide zone-specific ventilation. In one embodiment, ventilation openings 48 are concentrated near front edge 20 to increase airflow where heat accumulation is greatest. In another embodiment, openings 48 may be staggered or arranged in a diagonal or honeycomb pattern to enhance both structural integrity and airflow distribution.

[0038] In some embodiments, the ventilation openings 48 may intersect ridges 44 rather than being located entirely within grooves 46. In yet another embodiment, ventilation openings 48 may be selectively angled or contoured to direct airflow in a preferred direction relative to headgear movement or orientation.

[0039] Interior surface 42 includes a plurality of pins 60 arranged in multiple pin rows 62, which function as hair organization elements configured to engage and direct the wearer's hair. In the illustrated embodiment, pins 60 are arranged in various row configurations provided as examples. These include a plurality of front-to-back pin rows 82 (see FIG. 4), which, in one example, comprises ten rows arranged in parallel pairs and generally extending from front edge 20 to rear edge 22. The configuration also includes a plurality of side pin rows 84 (see FIG. 1), which, in one example, comprises four rows positioned along each side section of support structure 10. Additionally, at least one front edge pin row 86 (see FIG. 4) follows the contour of front edge 20 and extends partially along the side sections to provide frontal and lateral hair guidance. The number, spacing, and orientation of the pin rows may vary in alternative embodiments to achieve desired performance characteristics and accommodate different wearer needs.

[0040] Each pin 60 includes a pin base 70 that is integrally formed with interior surface 42 and a pin tip 68 configured to engage the wearer's hair. A fillet is provided at the junction between pin base 70 and interior surface 42 to create a smooth transition and reduce localized stress, thereby enhancing structural integrity and wearer comfort. Pin tips 68 are rounded or gently tapered to minimize discomfort and reduce the risk of scalp irritation during use. Pins 60 are angled relative to interior surface 42 by a pin angle , which in one example is approximately 65 degrees, as shown in FIG. 10. The length of each pin 60 is about 3 mm, for example. Minor variations in pin angle and length may be implemented in specific regions of the support structure 10 to optimize hair alignment and accommodate variations in scalp shape. In this regard, the pin angle may vary within each row or from row-to-row.

[0041] In alternative embodiments, the arrangement of pins 60 may vary to accommodate different hair types, densities, or user preferences. For example, pins 60 may be arranged in a spiral or radial pattern to direct hair away from a central point or in a staggered configuration to enhance engagement across variable scalp contours. In another embodiment, pin rows may be non-linear, following contoured or arcuate paths that mirror natural hair growth patterns or conform to ergonomic scalp topography. Additionally, pin density may vary across the interior surface 42. For instance, a higher concentration of pins 60 may be provided near front edge 20 to provide stronger retention, while fewer pins 60 may be used near rear edge 22 or sides edges 24 to enhance comfort.

[0042] As described, support structure 10 is configured to be compatible with a wide range of headgear types, each presenting unique functional requirements. With religious head coverings such as hijabs, support structure 10 provides volume maintenance while ensuring the fabric drapes naturally without slippage. For turbans, support structure 10 offers a stable foundation that maintains the wrapped fabric's position throughout daily activities. When used with wigs or hairpieces, support structure creates natural volume while securing the hairpiece firmly in place. For protective gear such as helmets, support structure provides additional comfort and stability while enhancing air circulation to reduce moisture buildup during extended wear. Fashion accessories such as hats benefit from improved positioning and reduced pressure against the scalp. The multi-directional friction provided by ridges 44 is helps accommodate the varying weights, textures, and draping characteristics of these different headgear types, making support structure 10 a versatile solution across diverse cultural, professional, and recreational contexts.

[0043] The exemplary support structure 10 described herein may be formed layer-by-layer using an additive layer manufacturing (ALM) process (i.e., 3D printing) such that all of its components are formed together as a single, integrated unit without assembly requirements. ALM refers to any manufacturing process where objects are built by adding material layer upon layer, as opposed to subtractive manufacturing methods where material is removed from a solid block or blank of a base material. In some examples, ALM processes are powder-bed based and involve one or more of selective laser sintering (SLS), selective laser melting (SLM), and electron beam melting (EBM). Other methods of ALM, which can be used to form the herein described support structure 10, include stereolithography (SLA), fused deposition modeling (FDM), Multi Jet Fusion (MJF), and continuous liquid interface production (CLIP).

[0044] When employing powder-bed based technologies, articles are produced in layer-wise fashion according to a predetermined digital model of such articles by heating (e.g., using a laser or an electron beam) multiple layers of powder, which may be a polymer powder, that are dispensed one layer at a time. The application of laser energy directed in raster-scan fashion sinters the powder in the case of SLS technology or melts it in the case of SLM technology, targeting portions of the powder layer corresponding to a cross section of the article. After the sintering or melting of the powder on one particular layer, an additional layer of powder is dispensed, and the process repeated, with sintering or melting taking place between the current layer and the previously laid layers until the article is complete. The powder layers similarly may be heated with EBM technology.

[0045] Support structure 10 may be made from one or more polymer materials using at least one of the aforementioned ALM processes. Such materials may be selected to provide for various advantages for wearing particular type of headwear, such as hijabs and the like, and/or to accommodate certain characteristics of the wearer. For example, support structure 10 may be made from nylon which may be suitable for wearers with normal to thick hair as it can provide a porous, spongy texture and a level of friction suitable to prevent slippage of lightweight, smooth fabrics. Nylon's balanced combination of rigidity and lightweight properties helps maintain the desired shape of the headgear while allowing sufficient air circulation to prevent heat buildup during extended wear periods, and its dimensional stability ensures the support structure maintains its form over time. In another example, support structure 10 may be made from thermoplastic polyurethane (TPU) which offers greater flexibility than nylon and may be more beneficial for individuals with thin or low-density hair. TPU's enhanced elasticity allows it to conform more closely to the head's contours, creating a more secure fit, while its higher coefficient of friction helps prevent slippage even with minimal hair contact, and its resilience enables it to return to its original shape after compression for consistent performance. In both of these examples, the material of support structure 10 may feature a microtexture in the 20-70-micron range that enhances the device's ability to interact with both hair and headgear fabrics without causing discomfort. Such texturing creates thousands of microscopic contact points that interact with individual hair strands and fabric fibers to help prevent slippage and to help distribute pressure evenly across contact surfaces.

[0046] Variations of support structure 10 may be configured to accommodate specific user groups and scalp types. For individuals with sensitive scalps, the pins 60 may feature softer tips, reduced density, or alternative geometries to minimize irritation while maintaining functionality. Pediatric versions may incorporate scaled dimensions, gentler pin angles, and enhanced flexibility to accommodate the unique head shapes and comfort requirements of children. For users with thicker hair or chemically treated hair types, pin configurations may be optimized with greater length, altered spacing, or specialized tip geometries to provide adequate engagement without tangling or causing damage to the hair structure.

[0047] In use, as illustrated in FIG. 11, support structure 10 is positioned on the wearer's head such that the front edge 20 sits just above the hairline, side sections 32 are proximate the ears and rearward of the wearer's temples, and center section 30 extends across the mid-scalp region of the head. Pins 60 pickup hair and nestle comfortably within it to produce a comfortable grip that helps secure support structure 10 in place. Pins 60 also help organize hair patterns to promote scalp aeration. Support structure 10, and particularly ridges 44, functions to elevate headgear away from direct contact with the hair and scalp, creating space for the hair to maintain volume and allowing air circulation via ventilation openings 48 for improved scalp health. Additionally, ridges 44 provide friction to prevent the overlying headgear from slipping, enhancing wearer confidence and comfort during extended use.

[0048] After support structure 10 is securely positioned on the head, headgear such as a hijab, for example, may be applied. When applying a hijab, the fabric is typically draped over the support structure 10, beginning at the front edge 20 and extending rearward to cover the entire support structure 10. The wearer may then secure or style the hijab according to personal preference or cultural requirements. During this application process, the ridges 44 immediately engage with the inner surface of the hijab fabric, creating multiple contact points that generate friction and prevent slippage in any direction. This engagement is particularly beneficial when turning or tilting the head, as the multi-directional grip pattern maintains the hijab's position without the need for excessive tightness or additional pins. The ventilation openings 48 continue to allow air circulation between the scalp and the hijab, reducing heat and moisture buildup that would otherwise accumulate during extended wear. The elevated structure created by support structure 10 maintains the natural contour and volume of both the hair and the hijab, providing an aesthetically pleasing appearance while ensuring long-term comfort and confidence for the wearer. Additionally, the spacing of ridged 44 not only promotes air circulation and grip, but also provides a flat appearance even for thin fabrics draped over support structure 10.

[0049] In some embodiments, an additional surface layer may be affixed or printed onto ridges 44 of exterior surface 40 to enhance grip on low-friction materials such as silk or chiffon. This layer may comprise a higher-friction material, a specialized texture, or a polymer coating specifically configured to interact with smooth fabrics that would otherwise be prone to slippage. The additional layer may be applied selectively to specific regions of the exterior surface 40/ridges 44, or it may cover the entire ridged area, depending on the intended application and headgear compatibility requirements.

[0050] In another embodiment, support structure 10 may comprise a partial arc extending across only a portion of the scalp, configured for use in sports or low-profile applications. This reduced-size version maintains various features of the full-sized embodimentincluding the ridged exterior surface 44, ventilation openings 48, and angled pins 82while covering a smaller area of the head. Such a configuration is particularly suitable for wearers with shorter hair, athletes requiring minimal headgear support during physical activities, or any application where a lower profile is preferred.

[0051] In some embodiments, support structure 10 may include or accommodate attachable modular elements, such as hair-securing clips, fabric overlays, or scarf anchors, affixed through mechanical or adhesive interfaces. These modular elements may be configured to enhance functionality, provide additional security, or adapt the support structure for specific types of headgear or hair configurations. The support structure 10 may include specialized connection points, indentations, or receptacles configured to receive these modular elements in a secure and user-friendly manner

[0052] Although the subject matter disclosed herein has been described with reference to specific embodiments, these are merely illustrative of the principles and applications discussed. Numerous modifications can be made to these embodiments, including combining features from different embodiments. Therefore, the exemplary embodiments are not intended to be exhaustive or to limit the disclosed subject matter.