Protective Headwear for Aquatic and Land Activities

Abstract

Protective headwear is described. The protective headwear may include an integrated protective shell. The integrated protective shell may include plastics or polymers and/or impact foam. The integrated protective shell may be housed by a cover, such as a fabric cover. The protective headwear may include a retention system, such as a chinstrap. The protective headwear may include a visor coupling feature that allows a visor to be securely held in a raised position to increase visibility.

Claims

1. A bump cap, comprising: a structural shell; and a housing coupled to the structural shell.

2. The bump cap of claim 1, wherein the structural shell comprises high-density polyethylene (HDPE).

3. The bump cap of claim 1, wherein the structural shell comprises impact foam.

4. The bump cap of claim 1, further comprising a retention system including a chinstrap.

5. The bump cap of claim 1, wherein the housing comprises a crown and a visor that may be selectively coupled to the crown in an upright position.

6. The bump cap of claim 5, wherein the visor may be selectively coupled to the crown via a visor coupling feature comprising at least one magnet.

7. The bump cap of claim 5, wherein the visor may be selectively coupled to the crown via a visor coupling feature comprising hook-and-loop fasteners.

8. Protective headwear, comprising: a crown; a visor coupled to the crown; and a protective shell coupled to the crown.

9. The protective headwear of claim 8, wherein the protective shell comprises high-density polyethylene (HDPE).

10. The protective headwear of claim 9, wherein the protective shell comprises impact foam.

11. The protective headwear of claim 9, wherein the protective shell comprises a set of fluid ports that allow air and water to pass through the protective shell.

12. The protective headwear of claim 8, where the protective shell includes a set of coupling features that couple a retention system to the protective headwear.

13. The protective headwear of claim 12, wherein each coupling feature in the set of coupling features comprises a through-hole and a structural support.

14. The protective headwear of claim 12, wherein each coupling feature in the set of coupling features comprises a bar tack portion that couples the protective shell to the crown.

15. The protective headwear of claim 12, wherein each coupling feature in the set of coupling features comprises a bar tack portion that couples the protective shell to the crown and to a retention system.

16. The protective headwear of claim 15, wherein the retention system comprises strapping, connectors, and complementary selective coupling elements.

17. The protective headwear of claim 8, wherein the visor may be selectively coupled to the crown in an upright position.

18. The protective headwear of claim 17, wherein the visor may be selectively coupled to the crown via a visor coupling feature comprising at least one magnet.

19. Headwear comprising: a crown; a visor coupled to the crown; a visor coupling feature that includes at least one magnet; and a complementary visor coupling feature that includes a ferromagnetic panel.

20. The protective headwear of claim 19, wherein the visor may be selectively coupled to the crown in an upright position via the visor coupling feature and the complementary visor coupling feature.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0003] The novel features of the disclosure are set forth in the appended claims. However, for purposes of explanation, several embodiments are illustrated in the following drawings.

[0004] FIG. 1 illustrates a top plan view of protective headwear of one or more embodiments described herein;

[0005] FIG. 2 illustrates a top plan view of the protective headwear of FIG. 1 including an exemplary integrated protective shell of one or more embodiments described herein;

[0006] FIG. 3 illustrates a right-side elevation view of the protective headwear of FIG. 1 including an integrated protective shell of one or more embodiments described herein;

[0007] FIG. 4 illustrates a right-side elevation view of the protective headwear of FIG. 1 with a visor coupling feature of one or more embodiments described herein;

[0008] FIG. 5 illustrates a top plan view of the protective headwear of FIG. 1 including an exemplary retention system of one or more embodiments described herein;

[0009] FIG. 6 illustrates a right-side elevation view of the protective headwear of FIG. 1 including the exemplary retention system of FIG. 5;

[0010] FIG. 7 illustrates a right-side elevation view of the protective headwear of FIG. 1 including another exemplary retention system;

[0011] FIG. 8 illustrates a front elevation view of the exemplary integrated protective shell of FIG. 2;

[0012] FIG. 9 illustrates a rear elevation view of the exemplary integrated protective shell of FIG. 2;

[0013] FIG. 10 illustrates a right-side elevation view of the exemplary integrated protective shell of FIG. 2;

[0014] FIG. 11 illustrates a left-side elevation view of the exemplary integrated protective shell of FIG. 2;

[0015] FIG. 12 illustrates a top plan view of the exemplary integrated protective shell of FIG. 2;

[0016] FIG. 13 illustrates a bottom plan view of the exemplary integrated protective shell of FIG. 2;

[0017] FIG. 14 illustrates a top, front, left-side perspective view of the exemplary integrated protective shell of FIG. 2;

[0018] FIG. 15 illustrates a top, rear, right-side perspective view of the exemplary integrated protective shell of FIG. 2;

[0019] FIG. 16 illustrates a right-side elevation view of an exemplary strap attachment feature of one or more embodiments described herein;

[0020] FIG. 17 illustrates a section view of an exemplary strap attachment feature of one or more embodiments described herein;

[0021] FIG. 18 illustrates a top plan view of the exemplary integrated protective shell of FIG. 2;

[0022] FIG. 19 illustrates a bottom plan view of the exemplary integrated protective shell of FIG. 2;

[0023] FIG. 20 illustrates a bottom plan view of the exemplary integrated protective shell of FIG. 2 and an exemplary set of impact absorbing features;

[0024] FIG. 21 illustrates a bottom plan view of an exemplary impact absorbing feature from the exemplary set of impact absorbing features of FIG. 20;

[0025] FIG. 22 illustrates a side elevation view of the exemplary impact absorbing feature of FIG. 21;

[0026] FIG. 23 illustrates a bottom plan view of a second exemplary impact absorbing feature from the exemplary set of impact absorbing features of FIG. 20; and

[0027] FIG. 24 illustrates a bottom plan view of a third exemplary impact absorbing feature from the exemplary set of impact absorbing features of FIG. 20.

DETAILED DESCRIPTION OF THE INVENTION

[0028] The following detailed description describes currently contemplated modes of carrying out exemplary embodiments. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of some embodiments, as the scope of the disclosure is best defined by the appended claims.

[0029] Various features are described below that can each be used independently of one another or in combination with other features. Broadly, some embodiments generally provide protective headwear for use during aquatic or land-based activities.

[0030] FIG. 1 illustrates a top plan view of protective headwear 100 of one or more embodiments described herein. In this example, the protective headwear 100 has a baseball cap style. Different embodiments of the protective headwear 100 may be implemented as various different styles, such as bucket hats, fedoras, boater hats, safari hats, trucker hats, beanies, berets, sun hats, bowler hats, Panama hats, and/or other appropriate types of headwear.

[0031] As shown, the protective headwear 100 may include a crown or covering 110, brim, visor, or bill 120, adjustable fastener 130, a visor coupling feature 140, and complementary visor coupling feature 150. The crown 110, visor 120, adjustable fastener 130, visor coupling feature 140, and complementary visor coupling feature 150, and/or other appropriate elements may be collectively referred to as a housing or cover. Various other elements of protective headwear 100 may be optional and/or omitted for clarity. Such elements may include, for instance, a brim 120 that spans the perimeter of the crown 110, a sweatband or liner, eyelets, buckram, and/or other appropriate elements.

[0032] Crown or covering 110 may include various types of fabrics and/or form factors, depending on user preferences and/or attributes (e.g., head size and/or shape). In some embodiments, the fabric may include fast-drying nylon and/or other materials appropriate for use in aquatic activities. In some embodiments, the fabric may be waterproof and/or provide sun protection.

[0033] Crown 110 may include multiple panels as shown.

[0034] Brim, visor, or bill 120 may be coupled to, integrated with, and/or otherwise associated with crown 110. For example, a portion of visor 120 and a portion of crown 110 may be sewn together and/or otherwise attached (e.g., via rivets, glue or other adhesives, etc.). The visor 120 may be able to block sunlight during use. Visor 120 may include fabric similar to, and/or appropriate for use with, crown 110. Visor 120 may include structural components such as a frame or support (e.g., a plastic panel enclosed between layers of fabric).

[0035] Adjustable fastener 130 may include various types of elements, as appropriate. For instance, adjustable fastener 130 may be, include, and/or utilize elements such as a snapback type closure, hook-and-loop closure, buckle closure, and/or other appropriate closures. In some embodiments, the crown 110 may be fitted or sized such that no adjustable fastener 130 is included (and/or is included or associated with a different element, such as a headband that may be otherwise coupled to the crown 110.

[0036] Visor coupling feature 140 and complementary visor coupling feature 150 may allow the visor 120 to be selectively coupled to the crown 110 such that a user may, for example, have a clear view when lying face-down on a surfboard. The visor coupling feature 140 and associated complementary visor coupling feature 150 may include components such as hook and loop fasteners, magnets (and/or ferromagnetic panels or components), snaps, buttons, zippers, and/or other appropriate fasteners that may be integrated with and/or otherwise coupled to crown 110 and/or visor 120. The visor coupling feature 140 and associated complementary visor coupling feature 150 may include, utilize, and/or be associated with various structural components, such as a backing or frame, additional layers of fabric, pockets and/or receptacles, etc. that may allow the visor coupling feature 140 and associated complementary visor coupling feature 150 to be securely integrated with and/or otherwise coupled to the crown 110 and/or visor 120.

[0037] In some embodiments, visor coupling feature 140 and/or other appropriate elements (not shown) may provide selective attachment features for various cameras, lights, tools, devices, and/or other objects. For instance, a camera may be coupled to a magnetic visor coupling feature 140. As another example, small tools, hardware, and the like, may be coupled to the visor coupling feature 140, associated complementary visor coupling feature 150, and/or other magnetic features such as rivets, grommets, snaps, buttons, etc. that may be strategically located along exterior surfaces of protective headwear 100.

[0038] As one example, visor coupling feature 140 may include at least one magnet that may be enclosed between layers of fabric and/or otherwise coupled to the visor 120 (and/or any associated structural components) and the complementary visor coupling feature 150 may include a ferromagnetic metal panel that may be enclosed by layers of fabric and/or otherwise coupled to crown 110 such that the visor coupling feature 140 is able to be selectively coupled to the complementary visor coupling feature 150 via attractive magnetic force between the magnet and ferromagnetic panel.

[0039] Continuing the example, the visor coupling feature 140 may be selectively decoupled from the complementary visor coupling feature 150 by overcoming the attractive magnetic force to separate the magnet from the ferromagnetic metal panel. Other types of fasteners (e.g., hook-and-loop, snaps, buttons, etc.) may be utilized in similar ways.

[0040] FIG. 2 illustrates a top plan view of protective headwear 100 including an exemplary integrated protective shell 200 (or structural shell) of one or more embodiments described herein. In this example, the integrated protective shell 200 is associated with baseball cap style headwear. Different embodiments of the protective shell 200 may be utilized for various different styles of headwear, such as bucket hats, fedoras, boater hats, safari hats, trucker hats, beanies, berets, sun hats, bowler hats, Panama hats, and/or other appropriate types of headwear.

[0041] Integrative protective shell 200 may be at least partially covered by, enclosed by, stitched to, adhered to (e.g., via a waterproof adhesive layer), and/or otherwise coupled to a housing that may include a crown 110 (and/or other appropriate sections of protective headwear 100). Integrated protective shell 200 may include, for example, plastics or polymers such as high-density polyethylene (HDPE), acrylonitrile butadiene styrene (ABS), silicone, etc. The integrated protective shell 200 may be molded, injected, and/or otherwise appropriately manufactured. The integrated protective shell 200 may have a thickness between one and five millimeters in some embodiments.

[0042] The integrated protective shell 200 (or portions thereof) may include, utilize, and/or otherwise be associated with a set of impact absorbing features such as a layer of impact foam (e.g., sealed closed-cell foam that includes polyethylene and/or other appropriate materials) and/or other impact-absorbing material or structural configuration (e.g., other types of impact absorbing foam, structural elements such as absorbers or springs, etc.). For instance, an interior wall of integrated protective shell 200 (or portions thereof) may be coupled to a layer of impact foam (e.g., via an adhesive layer), where the layer of impact foam may be between one and five millimeters thick in some embodiments. Such impact absorbing features are described in more detail in reference to FIG. 20 below.

[0043] Protective headwear 100 may be configured to be buoyant such that the protective headwear 100 floats on water. For example, the weight or mass of the protective shell 200 and/or fabric elements of protective headwear 100 may be offset by a complementary amount of impact foam such that the density of the protective headwear 100 enables the protective headwear 100 to float on water.

[0044] FIG. 3 illustrates a right-side elevation view of protective headwear 100 including an example integrated protective shell 200 of one or more embodiments described herein. The integrated protective shell 200 may include features such as air vents and water drainage ports 310. The shell may provide impact disbursement via features such as a set of leaf springs 320, where sections of the shell 200 are coupled along the perimeter of the shell 200, as shown.

[0045] FIG. 4 illustrates a right-side elevation view of protective headwear 100 with a visor coupling feature 140 and complementary visor coupling feature 150 of one or more embodiments described herein. In this example, the visor coupling feature 140 and complementary visor coupling feature 150 are selectively coupled together (e.g., by pressing together and/or aligning complementary features such as magnets and/or ferromagnetic panels, snaps, buttons, zippers, sections of hook-and-loop fasteners, etc.) such that the visor 120 is held in a raised, vertical, or upright position (i.e., a portion along the top surface of visor 120 may be secured to a complementary portion of the crown 110 as shown) such that the visor 120 does not impede sight lines of the user, in contrast to a lowered or horizontal position. Likewise, the visor coupling feature 140 and complementary visor coupling feature 150 may be selectively decoupled (e.g., by pulling apart complementary sections of hook-and-loop fasteners) such that the visor returns to a default or standard position.

[0046] Visor 120 may include structural elements (e.g., inserts, frames, supports, etc.) that may allow the visor 120 to maintain a horizontal position (i.e., the structural integrity of the visor 120 may prevent the visor coupling feature 140 and complementary visor coupling feature 150 from engaging unintentionally). Similarly, the visor coupling feature 140 and complementary visor coupling feature 150 may include elements (e.g., magnets, hook-and-loop elements, etc.) that may be strong enough to prevent the visor coupling feature 140 and complementary visor coupling feature 150 from decoupling unintentionally.

[0047] FIG. 5 illustrates a top plan view of protective headwear 100 including an exemplary retention system 500 of one or more embodiments described herein. As shown retention system 500 may include, utilize, and/or otherwise be associated with various appropriate elements, such as crown 110, integrated protective shell 200, various sections of strapping 510 such as braided nylon, connectors 520 such as Y-connectors, selective coupling element 530 and complementary selective coupling element 540, and/or a retainer 550 for excess strapping 510. The retention system 500 (or portions thereof) may be used as a chinstrap to secure the protective headwear 100 to a user.

[0048] Selective coupling element 530 and complementary selective coupling element 540 may include may and female components as shown, snaps or other fasteners, buckles, etc. Connectors 520, selective coupling element 530, and complementary selective coupling element 540 may include materials such as plastics or polymers (e.g., HDPE, ABS, etc.), metals, and/or other rigid and/or semi-rigid materials, as appropriate. In this example, connectors 520 may allow for floating or adjustable ear ports that may be adjusted by moving the connector 510 along the strapping 510 (e.g., making the ports larger by sliding the connector 510 along the strapping 510 away from the crown 110).

[0049] FIG. 6 illustrates a right-side elevation view of protective headwear 100 including exemplary retention system 500. In this example, retention system 500 is coupled to the protective headwear 100 at multiple coupling features 610. Such coupling features 610 may include elements such as through-holes, structural support panels, stitching or adhesives, backings, and/or other appropriate elements. An example coupling feature 610 is described in more detail in reference to FIG. 10, FIG. 16, and FIG. 17 below.

[0050] FIG. 7 illustrates a right-side elevation view of the protective headwear of FIG. 1 including another exemplary retention system 700. In this example, the exemplary retention system 700 may include a cord or similar element 710 that may be coupled to a feature similar to coupling features 610 (e.g., via adhesive, stitching, etc.). The exemplary retention system 700 may include strapping 510 that may be coupled to the cord 710 via a loop or similar feature 720.

[0051] FIG. 8 illustrates a front elevation view of exemplary integrated protective shell 200. As shown, the integrated protective shell 200 may be generally dome-shaped and may include an outer surface or wall 810 and an inner surface or wall 820.

[0052] FIG. 9 illustrates a rear elevation view of exemplary integrated protective shell 200. As shown, in this example integrated protective shell 200 has a rear cutout area for use with a baseball cap type protective headwear 100 that may include a snapback adjustable fastener 130. Different embodiments may not include such a cutout feature (e.g., integrated protective shells 200 intended for use with a fedora style hat).

[0053] FIG. 10 illustrates a right-side elevation view of exemplary integrated protective shell 200. As shown, multiple sections along outer wall 810 may serve as coupling features 610. An example coupling feature 610 is described in more detail in reference to FIG. 16 and FIG. 17 below. Different embodiments may include different numbers of coupling features 610 that may be located in various different places about integrated protective shell 200.

[0054] The integrated protective shell 200 may include a set of fluid ports 1010 that may serve as air vents and water drainage ports. In this example, the fluid ports 1010 are teardrop shaped, but different embodiments may include differently shaped ports (e.g., round, oval, triangular, etc.). The shell 200 may provide impact disbursement via features such as a leaf spring, where sections 320 of the shell 200 are coupled at the perimeter, as shown.

[0055] FIG. 11 illustrates a left-side elevation view of exemplary integrated protective shell 200. In this example, the coupling features 610 are symmetrical to those on the right side of integrated protective shell 200.

[0056] FIG. 12 illustrates a top plan view of exemplary integrated protective shell 200. As shown, each section or leaf spring 320 may be partially separated from adjacent sections 320 by a channel or gap 1210, thus allowing each section 320 to move independently as needed to absorb energy from impacts.

[0057] FIG. 13 illustrates a bottom plan view of exemplary integrated protective shell 200.

[0058] FIG. 14 illustrates a top, front, left-side perspective view of exemplary integrated protective shell 200.

[0059] FIG. 15 illustrates a top, rear, right-side perspective view of exemplary integrated protective shell 200.

[0060] FIG. 16 illustrates a right-side elevation view of an exemplary strap attachment feature 610 of one or more embodiments described herein. The strap attachment feature 610 may include elements such as a through-hole 1610 and/or a structural support 1620. Through-hole 1610 may accept a portion of strapping 510 or may allow multiple layers to be sewn together about the integrated protective shell 200. Structural support 1620 may include an area of the shell 200 that is thicker than other portions of the shell 200, includes various reinforcing elements (e.g., struts or other structural support elements) or materials (e.g., a metal plate), and/or otherwise provides structural support for a retention system 500.

[0061] FIG. 17 illustrates a section view of an exemplary strap attachment feature 610 of one or more embodiments described herein. As shown, the strap attachment feature 610 may include, utilize, and/or otherwise be associated with components such as a water resistant band 1710, strapping or webbing 510, portions of crown 110 (e.g., an interior hat band portion, an exterior cover, etc.), through-hole 1610, structural support 1620, and a bar tack region 1720 where the shell 200 may be securely coupled to the crown 110 (and/or other components of protective headwear 100) and/or strapping 510 (if included).

[0062] FIG. 18 illustrates a top plan view of exemplary integrated protective shell 200. As shown, integrated protective shell 200 may be symmetrical about center line or axis 1810. Line or axis 1820 may be perpendicular to line 1810. The section view of FIG. 17 may be along a line that is parallel to line 1820.

[0063] FIG. 19 illustrates a bottom plan view of the exemplary integrated protective shell 200. In this example, integrated protective shell 200 has a flat bottom surface that is parallel to line 1810. As such, integrated protective shell 200 may have a shape that is similar to an ellipsoid with some deviations to match typical user head shapes. In this example, the maximum height or depth of the integrated protective shell 200 is near line 1910, toward the rear portion of integrated protective shell 200. Line 1910 is perpendicular to line 1810 and line 1820.

[0064] In some cases, such as the cap-style protective headwear #0100 shown in FIG. 3 and FIG. 4, the bill 120 may be generally parallel to line 1810 and 1820 when in a lowered or horizontal position and the bill 120 may be generally parallel to line 1920 when in a raised or vertical position.

[0065] FIG. 20 illustrates a bottom plan view of the exemplary integrated protective shell 200 and an exemplary set of impact absorbing features 2010-2060 arranged along the inner surface or wall 820 of shell 200. In this example, the set of impact absorbing features 2010-2060 includes a separate feature for each leaf, but different embodiments may include different arrangements. For example, multiple impact absorbing features 2010-2060 may be coupled together via a band or strap that runs along the bottom perimeter of shell 200. In this example, shell 200 may be associated with cap-style protective headwear 100, where impact absorbing features 2010-2040 have the same shape, while impact absorbing features 2050-2060 may have different shapes to accommodate the opening above the adjustable fastener 130.

[0066] FIG. 21 illustrates a bottom plan view of an exemplary impact absorbing feature 2100 from the exemplary set of impact absorbing features 2010-2060. In this example, impact absorbing feature 2100 may be a specific implementation of impact absorbing features 2010-2040, which are associated with multiple similarly shaped leaves. As shown, impact absorbing feature 2100 may include a backing or support portion 2110, a set of impact absorbing regions 2120 associated with the backing 2110 (e.g., regions including impact foam coupled to the backing 2110).

[0067] FIG. 22 illustrates a side elevation view of the exemplary impact absorbing feature 2100. Backing 2110 may include, for example, one or more layers of fabric that may be coupled to sections of foam material (and/or other impact-absorbing materials) that at least partially form the impact absorbing features 2120. In some embodiments, two layers of fabric may be included in the backing 2110, where the layers of fabric may be coupled to the foam material via heat coupling (and/or other appropriate ways, such as stitching, adhesives, etc.). In some cases, the foam material may have a thickness of five to six millimeters before coupling to the backing 2110 and the backing 2110 and impact absorbing features 2120 may have an overall thickness of three to four millimeters after coupling. The impact absorbing features 2120 may be thicker near the center of each element and may be thinner near the perimeter of each element (e.g., at the heat pressing locations).

[0068] FIG. 23 illustrates a bottom plan view of a second exemplary impact absorbing feature 2300 from the exemplary set of impact absorbing features 2010-2060. In this example, impact absorbing feature 2300 may be a specific implementation of impact absorbing feature 2050.

[0069] FIG. 24 illustrates a bottom plan view of a third exemplary impact absorbing feature 2400 from the exemplary set of impact absorbing features 2010-2060. In this example, impact absorbing feature 2400 may be a specific implementation of impact absorbing feature 2060. As shown, the shapes of impact absorbing features 2300 and 2400 may conform to cap-style protective headwear 100 that includes a semicircle opening above an adjustable fastener 130.

[0070] One of ordinary skill in the art will recognize that the set of impact absorbing features may be implemented in various different ways without departing from the scope of the disclosure. For instance, some embodiments of the protective headwear 100 may include a single impact absorbing layer that covers most or all of the inner surface or wall 820. As another example, the set of impact absorbing features may include more than six elements. In addition, different embodiments may include various differently-shaped and/or arranged elements depending on the type, size, intended use, and/or other relevant attributes of protective headwear 100.

[0071] No element, act, or instruction used in the present application should be construed as critical or essential unless explicitly described as such. An instance of the use of the term and, as used herein, does not necessarily preclude the interpretation that the phrase and/or was intended in that instance. Similarly, an instance of the use of the term or, as used herein, does not necessarily preclude the interpretation that the phrase and/or was intended in that instance. Also, as used herein, the article a is intended to include one or more items and may be used interchangeably with the phrase one or more. Where only one item is intended, the terms one, single, only, or similar language is used. Further, the phrase based on is intended to mean based, at least in part, onunless explicitly stated otherwise.

[0072] The foregoing relates to illustrative details of exemplary embodiments and modifications may be made without departing from the scope of the disclosure. Even though particular combinations of features are recited in the claims and/or disclosed in the specification, these combinations are not intended to limit the possible implementations of the disclosure. In fact, many of these features may be combined in ways not specifically recited in the claims and/or disclosed in the specification. For instance, although each dependent claim listed below may directly depend on only one other claim, the disclosure of the possible implementations includes each dependent claim in combination with every other claim in the claim set.