Abstract:
A sweat absorbing pad for a human forehead which is filled with a fluid absorbing material or combination of materials such that the fluid and/or fluid absorbing materials are able to flow under pressure when saturated, the pad having channels with reduced flow resistance and which bias fluid flow toward the top and/or sides of the pad and away from the user&#39;s eyes.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to sweat absorption devices and systems, and particularly to human sweat absorption devices for being removably attached to the inside of a headgear article such as a cap, headband, helmet, goggle, visor and the like. 
         [0003]    2. Description of Related Art 
         [0004]    Removable sweat absorbers for being removably attached to the inside of a headgear article are known in the prior art but tend to suffer from one or more of the following performance and/or safety issues: 
         [0005]    A failure to control the absorbed perspiration within the absorber, resulting in the fluid being expelled as a result of pressure or impact on the absorber. For example, the impact on a helmet can compress the sweat absorber pad attached thereto, forcing the sweat and/or sweat absorbing media to be expelled. The expelled sweat and/or sweat absorbing media can be forced from the absorber toward the wearers eyes, causing irritation of the eyes and reduced visibility. At the very least, the irritation of the eyes is an uncomfortable distraction to the user, resulting in a momentary lapse of concentration. However, even a momentary lapse of concentration during competitive sports could have adverse consequences in the performance of the user. At the more severe end of the spectrum, the temporary impairment of vision that often results when the irritant enters the eyes could jeopardize the safety of the user, particularly during participation in activities involving high speeds or requiring significant concentration. 
         [0006]    A lack of ability to conform to the wearer&#39;s forehead and/or the inside of headgear in order to maximize the perspiration absorbing surface area in contact with the user. 
         [0007]    A lack of a saturation level indicator to indicate the approximate level of moisture saturation of the absorber. 
         [0008]    A lack of a removal tab to aid in the removal of the absorber from the headgear article after use in a sanitary manner in which direct contact with the perspiration is avoided. This may be of importance in situations where a person other than the user is responsible for the cleaning or maintenance of the headgear article, such as an equipment manager or coach. 
         [0009]    Perspiration that has been absorbed in the absorber tends to pool or accumulate in the lowest area of the absorber, which often becomes over saturated with moisture, reducing the effectiveness of the absorber. 
         [0010]    Accordingly, an improved perspiration absorption system that solves one or more of the above problems would be desired. 
       SUMMARY OF THE INVENTION 
       [0011]    The present invention provides perspiration absorption systems that are adapted to being removably attached to the inside of a headgear article such as, but not limited to, a cap, headband, helmet, goggle, visor and the like. 
         [0012]    In some embodiments, the present invention provides a sweat absorbing pad for a human forehead which is filled with a fluid absorbing material or combination of materials such that the fluid and/or fluid absorbing materials are able to flow under pressure when saturated, the pad having channels with reduced flow resistance and which bias fluid flow toward the top and/or sides of the pad and away from the user&#39;s eyes. The pad preferably includes a fluid impervious seal along the lower edge of the pad to prevent fluid from leaking and/or bursting out of the pad toward the user&#39;s eyes. One or more reliefs or cutaway portions are preferably provided along at least the top edge to allow the pad to conform to a curved concave inner surface of a human headgear and/or the curved convex surface of a human head. In some embodiments, the pad may be provided with air flow openings which correspond with air flow openings in the headgear to allow air flow through the headgear. The pad is preferably self adhesive to the headgear. In some embodiments, the pad comprises sealed valves or zones along the top and/or sides which prevent fluid leakage at low pressures and allow fluid to flow past the seal at elevated pressures such as during an impact but with a lower pressure than would be necessary to causes fluid to leak or burst through the seal along the lower edge of the pad. In some embodiments, the pad includes one or more sanitary removal tabs which adhere or otherwise attach to the outside of the headgear. A visible saturation indicator may be provided in some embodiments. 
         [0013]    In some embodiments, the device includes two or more horizontally biased fluid chambers/channels which prevent absorbent material from pooling toward the lower edge of the pad. 
         [0014]    In some embodiments, the pad uses a phase change material to modulate/affect the temperature of the skin in contact with the pad. 
         [0015]    In some embodiments, the present invention provides a sweat absorbing pad for use in headgear, the pad comprising a backing layer having securing means adapted for removably securing the pad to an inside surface of the headgear, a skin facing layer that allows perspiration to pass therethrough and which is attached to the backing layer along a plurality of seams, moisture absorbing material between the backing layer and the skin facing layer, wherein the seams define channels in the moisture absorbing material with reduced resistance to the flow of fluid and which bias fluid flow toward the top and/or sides of the pad and away from the user&#39;s eyes. A fluid impervious seal may be provided along a lower edge of the pad to prevent fluid from leaking and/or bursting out of the pad toward the user&#39;s eyes. As well, one or more reliefs or cutaways may be provided along at least the top edge to allow the pad to conform to a curved concave inner surface of an article of human headgear and/or a curved convex surface of a human head. In some embodiments, sealed valves or zones are provided along the top and/or sides which prevent leakage at low pressures and allow fluid to flow past the seal at elevated pressures such as during an impact but with a lower pressure than would be necessary to causes fluid to leak or burst through the seal along the lower edge of the pad. One or more sanitary removal tabs may be provided that adhere or otherwise attach to the outside of the headgear. A visible saturation indicator may be provided. In some embodiments, the pad includes two or more horizontally biased fluid chambers/channels defined in the absorbent material which prevent absorbent material from pooling toward the lower edge of the pad. The skin facing layer may comprise a phase change material to modulate the temperature of the skin in contact with the pad. 
         [0016]    The sanitary absorber is preferably attached to the host headgear with a mild adhesive that does not damage or leave adhesive residue, or affect the intended performance of the headgear. An adhesive is preferable to a hook and loop type fastener because it is thinner and consequently will have a lesser effect on the performance and fit of the headgear. The primary function of the sweat absorbing system is to adsorb sweat, bacteria and/or other fluid that can accumulate above and/or around the eyes. The absorber is designed as a disposable product that is removed after use by means of the sanitary removal tab. The sanitary removal tab also serves the purpose of making it obvious to the user which is the lower edge of the pad to insure that the pad is adhered to the headgear in the correct position with the sealed edge along the bottom closest to the eyes. The absorber is designed to ensure that, if used in a helmet, it does not interfere significantly with the intended design of the helmet. Control of the direction of flow of the absorbing gel or other absorbent material during an impact is crucial to maintaining the clear vision of the user, especially during a stressful situation. Flow channels or conduits are integrated into the absorber to compartmentalize the suspended fluid and to bias the flow of the absorbent gel (or other absorbent material) toward “blow off&#39; valves or zones along the top and/or ends of the pad to direct expelled gel and/or other absorbent material and/or fluid away from the wearer&#39;s eyes during an impact or pad compression event. The channels or conduits and seals between channels or conduits are not necessarily on the outer surface or inner surface. They separate absorbent material chambers, preferably as a result of the outer and inner layers being adhered together. The blow off valves or zones are sealed under normal pressure but become unsealed at a lower pressure than the sealed area along the lower edge of the pad. In addition to blow off valves or zones, a stretchable or folded membrane, film or other expandable material can be used to allow the gel or other absorbent material and/or fluid to be expelled from the blow-off valves or zones or controlled leakage areas while keeping the fluid or gel from contacting the user or their headgear. By allowing the absorber to blow the fluid upward and/or outward, the absorber will help dissipate the energy during the impact and also go down to a very thin structure to minimize interference with the intended energy dispersing performance of the helmet. 
         [0017]    The sweat management system of the present invention is preferably a disposable (but may be reusable) product that is removably secured to the inside of an article of headgear by means of a light adhesive or other securing means such as, but not limited to, a hook and loop fastening system. The present invention provides a sanitary sweat absorbing pad which provides maximum contact with the user&#39;s forehead by means of one or more pre-formed relief shapes in the absorbing pad which allow a flat pad to conform to a convex curved surface, such as the inside of a headgear article. 
         [0018]    The pad is preferably manufactured as a planar (flat) die-cut shape, which is preferably generally comprised of a minimum of a porous or partially porous or sweat permeable facing layer for abutting against the skin of the wearer, a backing sheet or layer on the opposite side of the pad and having a securing means for securing the pad to the inside of a headgear article such that the facing layer is able to come into contact with the skin of the wearer at a desired location, and highly absorbent material or materials sandwiched between the facing layer and the backing sheet. In some embodiments, the securing means comprises an adhesive on the backing sheet and release paper thereon that is removed before applying the pad to the inside of the headgear article. Other layers or components for absorption and/or retention and/or expelling of fluid may also be used in addition to the above construction. 
         [0019]    Many different absorbing materials may be used alone or in combination including, but not limited to, webs of carded or airlaid textile fibers, multiple plies of creped cellulose wadding, pulp fiber, various absorbent and super absorbent materials, absorbent and super absorbent hydrogels, absorbent and super absorbent liquid absorbing hydrogel-forming polymers, peat materials or other natural absorbent materials, synthetic foam sheets or the like. The preferable material is a liquid absorbing hydrogel-forming polymer composition such as is used in other common liquid absorbing products such as diapers or sanitary napkins. Examples of this kind of material are sodium polyacrylate and sodium acrylate. These materials are often used in combination with a binder such as a matrix of fibrous or porous fibrous cellulose fibers. These liquid absorbing hydrogel-forming polymers can absorb and retain significant volumes of liquid. When used for perspiration absorption, they offer a tremendous advantage in performance and safety for people such as athletes, law enforcement officers or military personnel (to list a few examples). However, If a pad comprised of these known absorbent material is not designed in accordance with the present invention—such a pad could leak or burst during applied pressure or impact, and the saturated absorbent material (and/or the absorbed perspiration) can be expelled toward the user&#39;s eyes. This represents a significant performance and/or safety risk which the present invention overcomes. 
         [0020]    The present invention, by providing flow channels or perspiration conduits which bias the flow direction upward and/or outward, enable the benefits of a highly absorbent material to be realized without the associated risk of expelling sweat or saturated gel toward the user&#39;s eyes. Each of these flow channels is preferably constructed to significantly reduce or prevent leakage of the absorbent material during normal use, but to allow the saturated absorbent material and/or the absorbed perspiration to escape through lower resistance flow zones along the top and/or ends/outer edges of the absorber pad if it is pressurized during an event such as an impact. The boundaries of these flow channels or flow zones can be of a number of different designs or constructions, but are preferably pressure sealed and/or heat sealed and/or adhesive sealed in a manner such that the resilience of these seals is high enough to prevent leakage during normal use and to prevent bursting of the seal along the lower edge of the pad nearest the user&#39;s eyes during a elevated pressure event such as an impact. The low resistance flow zones along the top of the pad and or the sides/outer edges can be of a number of different designs, but are preferably pressure sealed and/or heat sealed and/or adhesive sealed in a manner such that the seal fails under sufficient pressure and at a lower pressure than the seal along the bottom edge closest to the user&#39;s eyes. 
         [0021]    An additional advantage of allowing the sweat and/or sweat absorbing material to escape through these lower resistance flow zones is the minimal effect that the sweat management system will have on the performance of a helmet during impact. In other words, with the saturated material being allowed to flow out of the pad (but directed away from the wearer&#39;s eyes) during an impact, the energy absorbing qualities of the helmet padding are minimally affected and the force of the impact can be spread over a larger area than the pad (as the helmet is originally designed to do). 
         [0022]    In some embodiments of the invention, the absorbent gel or other saturated material is prevented from escaping completely from the absorber pad by a thin expandable or stretchy membrane, thereby preventing the gel from contacting the users hair, head or helmet. 
         [0023]    In some embodiments, a sanitary removal tab is preferably attached to the pad along an edge at a the location which depends on the specific embodiment of the present invention and its intended application. For example, in an embodiment for use with helmets and hats, the removal tab may be located on the lower edge of the pad. An embodiment for use with goggles and the like, the removal tab could be located on the upper edge. Preferably, the location of the removal tab is such that it does not interfere with the use of the headgear or the activity the user is engaged in, yet allows the tab to be readily grasped when the user or other person wishes to remove the absorber pad from the headgear. In some embodiments, the removal tab is long enough to wrap around a portion of the helmet or other type of headgear, and includes an adhesive portion that enables the removal tab to be adhered to the outside of said headgear. In some embodiments, the end of the tab preferably has a non-adhesive portion which makes it easier to grasp the tab. Advantageously, the removal tab allows a sweat saturated absorber pad to be removed from the headgear without the user (or someone else such as a coach, trainer or equipment manager) having to contact the sweat absorbing portion of the pad. 
         [0024]    In some embodiments, the removal tab may include a visual indicator for displaying to the wearer the load saturation of the absorbent material (i.e. the amount of fluid absorbed) by means of an electronic and/or color change in the material. This may be crucial information for a trainer who is tasked with visually monitoring athletes during performance for signs of dehydration. Many instances of miss-diagnosing an athlete&#39;s hydration levels have resulted in serious health consequences, including death. A visual indicator of load saturation provides information on which the wearer&#39;s hydration levels may be more accurately determined. And this is especially important in speed related activities such as cycling and motorcycling where the loss of fluid through perspiration can be difficult to estimate as a result of the drying effect of the apparent wind. 
         [0025]    A number of different indicator technologies may be used. For example, the electrical resistance across the length or width of the pad could be used to determine the moisture content and an LED or other display (such as, but not limited to, paper thin TV technology developed by Siemens company of Germany) may be used to indicate the saturation level of the pad. Other technologies that rely on chemical composition changes or a build up of minerals or electrolytes in the pad as a result of increased perspiration load in the pad to produce a change in the color of the indicator may also be used. Of course, other suitable indicator technologies are known in the art and may be used herein, and the inventors contemplate that indicator technologies will be developed in the future that may also be suitable for use with the present invention. 
         [0026]    The sweat system of the present invention can be produced with different thicknesses to allow for different saturation capacities. In some embodiments, the indicator may include a graphic or numeric indication of what percentage of the absorber&#39;s capacity has been utilized. 
         [0027]    In some embodiments, the outer fabric on the facing layer that interfaces with the wearers skin can be made of phase changing material including, but not limited to material marketed as OUTLAST (trademark) material, which is manufactured by Dupont. Such material will help control the wearers temperature during use. 
         [0028]    The pad is preferably designed with two or more horizontally biased fluid chambers/channels which prevent the absorbent material from pooling toward the lower edge of the pad as it becomes saturated. 
         [0029]    Many different configurations of this invention are possible and anticipated by the inventors. The purpose of this disclosure is to describe several variations of preferred embodiments of the invention. 
         [0030]    The invention may also be designed with air flow openings to allow airflow through the pad. Specific pad shapes can be produced with air flow openings that correspond with air flow openings in the specific piece of head gear for which they are intended (such as, but not limited to a specific type of bicycle helmet, goggle, motorcycle helmet and the like) to allow air flow through the headgear. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0031]    Referring now to the attached drawings which form a part of this original disclosure: 
           [0032]      FIG. 1  is a front view of the inside facing layer of an embodiment of a sweat management absorber pad of the present invention; 
           [0033]      FIG. 2  is a front view of the backing layer of the embodiment in  FIG. 1 ; 
           [0034]      FIG. 3  is a cross section view along line A-A of the embodiment in  FIG. 1 ; 
           [0035]      FIG. 3   a  is a partial cross section view of another embodiment that has an expandable membrane at the top edge; 
           [0036]      FIG. 4  is a front view of the inside facing layer of another embodiment of a sweat management absorber pad of the present invention; 
           [0037]      FIG. 5  is a front view of the inside facing layer of yet another embodiment of a sweat management absorber pad of the present invention; 
           [0038]      FIG. 6   a  is a perspective view from the top of the embodiment in  FIG. 1  shown in a conformed configuration; 
           [0039]      FIG. 6   b  is front view of the embodiment in  FIG. 1  shown in a conformed configuration; 
           [0040]      FIG. 6   c  is a back view of the embodiment in  FIG. 1  shown in a conformed configuration; 
           [0041]      FIG. 6   d  is a side view of the embodiment in  FIG. 1  shown in a conformed configuration; 
           [0042]      FIG. 6   e  is a perspective view from the side of the embodiment in  FIG. 1  shown in a conformed configuration; 
           [0043]      FIG. 7  is a perspective view from the side of yet another embodiment of a sweat management absorber pad of the present invention that is adapted to being used on a goggle; and 
           [0044]      FIG. 8  is a perspective view from the side of the inside facing layer of the embodiment in  FIG. 7 . 
       
    
    
     DETAILED DESCRIPTION 
       [0045]    Referring to  FIGS. 1 to 3 , a sweat management absorber pad  10  in accordance with an embodiment of the present invention is illustrated. The absorber pad  10  includes a porous or semi-porous inside facing layer  12  adapted to contact the skin on a wearer&#39;s forehead and which allows perspiration to pass through to absorbent material  16  underneath the facing layer  12 . The absorber pad  10  further comprises a backing layer  14  adapted to being secured to an inside surface of a piece of headgear, such as (but not limited to) a helmet, hat, cap, goggle or the like. In between the facing layer  12  and the backing layer  14  is provided an absorbent material  16 , and the two outside layers ( 12  and  14 ) are connected to each other along seams  18  and the peripheral edges. The seams can be of a number of different designs or constructions, but are preferably pressure sealed and/or heat sealed and/or adhesive sealed. The seams  18  provide the boundaries that define channels or chambers of absorbent material  20  that act as flow channels during impact to direct fluid and/or gel and/or other absorbent material away from the eyes of a wearer of the headgear. Multiple flow channels  20  are provided to limit or prevent absorbent material from pooling or gathering along the bottom seam or bottom edge  24  of pad. The seal along bottom edge  24  is preferably strong enough to prevent leakage during normal use and to resist bursting during an elevated pressure event such as an impact, to prevent absorbent material and/or accumulated perspiration from leaking or bursting toward the eyes. 
         [0046]    The absorber pad  10  further includes relief cutaway portions  28  that allow the pad to conform concave curved inner surface of the particular headgear article for which the pad is intended. 
         [0047]    Flow zones  30  along the top  25  and/or sides (not shown in this example) are sealed at normal pressure but allow fluid to flow out of the pad at higher (impact etc.) pressures. 
         [0048]    A flexible sanitary removal tab  32  adheres to outside of headgear and allows removal of pad without contacting the sweat saturated portions of the absorber pad  10 . The tab  32  preferably has saturation level indicator  34  and non-adhesive section  36  which allows it to be easily grasped. 
         [0049]    Referring to  FIG. 2 , the backing layer  14  is shown, which in preferred embodiments includes an adhesive layer for securing the pad to inside of headgear. Relief cuts  28  allow the pad  10  to conform concave curved inner surface of the user&#39;s headgear. Flow zones  30  along top and/or sides (not shown in this example) are sealed at normal pressure but allow fluid to flow out of pad at higher (impact etc.) pressures. The seal along bottom edge  24  prevents absorbent material and or perspiration from leaking or bursting toward the wearer&#39;s eyes. The sanitary removal tab  32 , which is generally thin, is adapted to bending around bottom rim or edge of the headgear, and it includes an adhesive portion that adheres to outside of headgear to keep it out of the way. The sanitary removal tab  32  allows removal of pad without contacting the saturated material. The tab  32  preferably has a non-adhesive portion  36  which allows it to be easily grasped. 
         [0050]    Referring to  FIG. 3 , the sweat management absorber pad  10  is illustrated in cross section along section line A-A. The facing layer  12  and the backing layer  14  are shown, as is the absorbent material  16  that is divided by seams  18  between the layer  12  and  14  into flow channels  20 . 
         [0051]    Referring to  FIG. 3   a , an embodiment of the pad is shown in partial cross section which includes a flexible membrane  27  at the top edge  25 . The expandable membrane  27  basically comprises of a folded film or membrane which expands as a result of pressure build up in the pad. 
         [0052]    The pad may include less resilient seal/flow zones along all or part of top edge (or any edge which would not eject absorbent material or perspiration toward user&#39;s eyes). This seal/flow path, can be an adhered section or integrated restricted flow valves etc. 
         [0053]    The seal at seams  18  between flow chambers  20  and along bottom edge  24  are more resistant to leakage than the seam along top edge  25 . This biases fluid flow out the top edge  25  of the pad if pad is compressed, such as during impact. The seams can be achieved by sewing, heat bonding, or adhesives, or any other method of attaching the inner facing and outer backing layers ( 12  and  14 ) of material. 
         [0054]    An adhesive on backing layer  14  secures the pad to inside of headgear. The material of the facing layer  12 , which comes in contact with the user&#39;s head, allows perspiration to pass through to the absorbent material  16 . 
         [0055]    Referring to  FIG. 4 , another embodiment of a sweat management absorber pad  100  in accordance with the present invention is illustrated. The basic construction is similar to pad  10 , the principal variations in pad  100  being that the flow channels  120  defined by the internal seams  118  bias the absorbent material and fluid towards the side edges  122 , where the flow zones  130  along sides/ends are sealed at normal pressure but allow fluid to flow out of pad  100  at higher (impact etc.) pressures. The seal along bottom edge  124  functions as that in pad  10  to prevent absorbent material from leaking or bursting toward eyes. 
         [0056]    Referring to  FIG. 5 , another embodiment of a sweat management absorber pad  200  in accordance with the present invention is illustrated. The basic construction is similar to pad  10 , the principal variations in pad  200  being that there are no internal seams such that there are no multiple flow channels. Rather the flow zones  230  along top edges that are sealed at normal pressure but allow fluid to flow out of pad at higher (impact etc.) pressures facilitate the movement of fluid upward through the pad. The seal along bottom edge  224  functions as that in pad  10  to prevent absorbent material from leaking or bursting toward eyes. 
         [0057]    Referring to  FIG. 6 , the sweat management absorber pad  10  is illustrated, in a number of views (a to e), in a configuration in which the pad  10  conforms in shape to the inside surface of an item of headgear. The sanitary removal tab  32  is shown in a configuration prior to it being bent around and adhered to the outside of the headgear, except in  FIG. 6   d  in which the tab  32  is shown in an adhered configuration in which it would be bent around a rim of the headgear and adhered to the outside surface of the headgear. 
         [0058]    Referring to  FIGS. 7 and 8 , another embodiment of a sweat management absorber pad  300  in accordance with the present invention is illustrated. Pad  300  is adapted to being used in conjunction with goggles, such as ski goggles  6 . The construction of pad  300  is basically similar to pad  10 , namely it comprises an inside facing layer  312  of a porous or semi-porous material adapted to contact the skin on a wearer&#39;s forehead and which allows perspiration to pass through to absorbent material underneath the facing layer  312 . The pad includes a backing layer  314  that has an adhesive for securing the pad to the inside top seal of the goggle which contacts a wearer&#39;s forehead during use. The two layers  312  and  314  enclose an absorbent material, and are connected to each other by seams  318  (which may be sealed or semi-sealed) that define flow channels  320  that are biased towards the sides of the pad  300 . The seal along bottom edge  324  is strong enough to prevent absorbent material from leaking or bursting towards the wearer&#39;s eyes. Flow zones  330  along top  325  and/or sides are sealed at normal pressure but allow fluid to flow out of the pad  300  at higher (impact etc.) pressures. 
         [0059]    Connected along the top edge  325  of the pad  330  is a flexible flat panel portion  328  that is adapted to fit over the top edge of the goggle, and which includes holes  329  therein that correspond to the vents in the goggle to enable unimpeded venting of the goggle. The flat panel portion  329  is articulated relative to the absorbent portion of the pad  300  along fold  331 , which allows the pad  300  to conform to the shape of the goggle. In some embodiments, the flat panel portion may comprise of a mesh material which allows air flow there through, in which case holes  329  would not be required. A relief cutaway portion  328  are preferably provided to allow pad  300  to conform to the concave curved inner surface of the goggle. One or more sanitary removal tabs  332  are provided which bend around top edge of goggle and adheres to outside surface. The tabs  332  also facilitate the removal of pad without contacting the saturated absorbent material. One of the tabs  332  may be provided with a saturation level indicator and non-adhesive section similar to the other embodiments of the present invention. 
         [0060]    While only selected embodiments have been chosen to illustrate the present invention, it will be apparent to those skilled in the art from this disclosure that various changes and modifications can be made herein without departing from the scope of the invention as defined in the appended claims. Furthermore, the foregoing description of the embodiments according to the present invention are provided for illustration only, and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.