Abstract:
This invention relates to a protective headgear for use by wrestlers and other athletes who require protective covers for their ears during practice and contests. The headgear provides shock absorbency and protection for the ears and forehead in an easily adjustable and comfortable device that is also disassemblable and interchangeable for ease of repair.

Description:
FIELD OF THE INVENTION  
       [0001]     This invention relates to a protective headgear for use by wrestlers and other athletes who require protective covers for their ears during practice and contests. The headgear provides shock absorbency and protection for the ears in an easily adjustable and comfortable device that is also disassemblable and interchangeable for ease of repair.  
       BACKGROUND OF THE INVENTION  
       [0002]     Amateur wrestlers are subjected to maneuvers and contact with opponents and the wrestling mat which can result in injuries to the outer ear surfaces. Such injuries can be the result of unintentional blows to the ear by opponents, abrasion by sliding contact with the mat, i.e., mat burn, and unintentional head contact between opponents, i.e., head butts. As a means of protecting against such injuries, ear protective devices are in wide-spread use and generally provide a pair of reinforced cup shaped protectors designed to cover the ears and connected by a plurality of generally adjustable straps to form a complete headgear wearable by wrestlers during a match.  
         [0003]     Reinforced protectors are allowed in high school, college and amateur wrestling leagues in the United States and are well known. Such reinforced ear protectors include those described in the present inventor&#39;s prior patents, U.S. Pat. No. 5,504,945 and U.S. Pat. No. 6,058,516 as well as those ear protectors exemplified by Marchello, U.S. Pat. No. 3,596,288 and U.S. Pat. No. 4,821,354, Dubner, et al., U.S. Pat. No. 4,710,985, Keen, U.S. Pat. No. 2,898,596, Johnson U.S. Pat. No. 537,686, Roberts, U.S. Pat. No. 2,277,994 and U.S. Pat. No. 2,886,818, Helm, U.S. Pat. No. 3,311,921, Pukish, Jr., U.S. Pat. No. 3,327,317, and Holden U.S. Pat. No. 3,513,482. However, these protectors are not readily changed or disassembled to facilitate repair or changes in outward appearance to, for example, match uniform colors. In addition some of the prior art ear protectors having rigid shells can themselves cause injury when the shells project through any surrounding padding or other covering.  
         [0004]     Accordingly, there is a need in for an ear protector that meets the requirements for protection and safety of wrestlers without rigid shells. It would also be useful if such an ear protector were easily assemblable and disassemblable so as to facilitate changing parts for repair or reconfiguration of the device.  
         [0005]     The present invention addresses these needs in an ear protector that meets the international requirement of non-rigidity, while providing sufficient protection, that is fully adjustable to accommodate different sized wrestlers, and that is easily assembled or disassembled to facilitate changing pieces that become worn or broken through use or to change the outward appearance of the ear protector.  
       SUMMARY OF THE INVENTION  
       [0006]     The present invention is an improvement over the prior art and provides an ear protector construction resulting in better protection to both the wearer and his opponent and which provides a degree of shock absorbency not found in similar devices and provides protection without a rigid shell while also providing a greater degree of air flow to the ear. In addition, the invention provides a protective ear guard assembly that is fully adjustable for optimum comfort and protection as well as being easily disassemblable for repair or reconfiguration.  
         [0007]     The present invention provides a lightweight disassemblable and interchangeable protective headgear for wrestling comprising,  
         [0008]     a left side ear protector,  
         [0009]     a right side ear protector, and  
         [0010]     a plurality of adjustable straps,  
         [0011]     forming a wearable assembly, wherein each ear protector comprises an outer cage structure, an inner perforated dome structure, and a peripheral resilient pad, said ear protectors adapted to fit over a wearer&#39;s ear whereby said dome structure fits over and receives the wearer&#39;s outer ear, said outer cage and said inner dome structures provide shock and blow protection for the wearer&#39;s ear and said resilient pad provides cushioning between said ear protectors and the wearer&#39;s head.  
         [0012]     The present invention further provides a lightweight, disassemblable and interchangeable protective wrestling earguard assembly comprising a pair of matching ear guards, each ear guard comprising;  
         [0013]     a semi-rigid outer cage structure comprising a peripheral flange defining a central space and having an inner surface and an outer surface, a plurality of bars extending from said outer surface arcuately upward and over said central space forming a substantially cup shaped cage, and means on said flange to receive a plurality of adjustable straps,  
         [0014]     a semi-rigid inner dome structure comprising a peripheral flange defining a central space substantially corresponding to said central space of said cage structure and adapted to cooperate with said peripheral flange of said cage structure, a cup shaped center portion extending over said central space and comprising a plurality of spaced ribs connected by an intermediate web, said cup shaped center portion being receivable within said cup shaped cage, and  
         [0015]     a resilient foam pad substantially corresponding to said flange of said outer cage structure and positionable over said inner surface of said flange of said outer cage structure so as to be disposed between said flange and a wearer&#39;s head, whereby said inner dome structure fits within said outer cage structure and said resilient foam pad fits over said flange to form said ear guard whereby said cup shaped center portion of said inner dome structure receives the outer ear of a wearer when said ear guard is placed thereover and said outer cage structure and said inner dome structure cooperate to provide protection for said ear against shock and direct blows.  
         [0016]     Thus, it is an object of this invention to provide an improved protective headgear for wrestlers.  
         [0017]     It is a further object to provide an improved protective headgear that meets international regulations while providing a degree of shock absorbency and ease of adjustment.  
         [0018]     It is a still further object to provide an improved protective headgear that is easily repaired and/or reconfigured.  
         [0019]     Further objects and advantages will become evident from the following drawings and descriptions. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0020]      FIG. 1 . is a view of the headgear of the present invention.  
         [0021]      FIG. 2 . is a view of the outer surface of the outer cage of the ear protector structure of the present invention.  
         [0022]      FIG. 3 . is a view of the inner surface of the outer cage of the ear protector structure of the present invention.  
         [0023]      FIG. 4 . is a view of the outer surface of the inner perforated dome of the ear protector structure of the present invention.  
         [0024]      FIG. 5 . is a view of the inner surface of the inner perforated dome in place within the outer cage of the ear protector structure of the present invention.  
         [0025]      FIG. 6 . is a planar view of the underside of the peripheral resilient pad of the ear protector structure of the present invention.  
         [0026]      FIG. 7 . is a planar view of the upper side of the peripheral resilient pad of the ear protector structure of the present invention.  
         [0027]      FIG. 8 . is an upper oblique view of the assembled ear protector structure of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0028]      FIG. 1  illustrates the protective headgear assembly  1  of the present invention as worn by a wrestler. The assembly comprises left and right ear protectors  2  and  3  joined together in wearable form by adjustable head straps  4  and an adjustable chin strap  5 , preferably with a resilient foam pad or chin cup  6 . Straps  4  and  5  are preferably woven fabric with releasable hook and loop fastenings at each end providing ease of use and adjustment. Chin strap  5  further has releasable fasteners, such as snaps, to engage corresponding snap fasteners  16  on each ear protector.  
         [0029]     As shown in  FIG. 1 , the left and right ear protectors  2  and  3  of the headgear assembly  1  are substantially mirror images and each comprises an outer cage  7 , an inner perforated dome  8  and a peripheral resilient pad  9 . These three elements fit together in a separable manner such that, by releasing the head straps  4  and chin strap  5 , the cage  7 , dome  8 , and pad  9  may be separated for ease of replacement of any or all three of the elements.  
         [0030]     Turning to  FIGS. 2 and 3 , the outer cage  7  is molded from a reinforced or non-reinforced polymer, such as polyurethane, polyvinyl chloride, hytrel, thermoplastic urethane, or the like, with a durometer in the range of 70-90, preferably 80-85. Preferably, the polymer is non-reinforced PVC or TPU so as to provide the desired degree of flexibility and resilience for shock absorbance and deflection. If desired, reinforcing material may be incorporated into the polymer when molding the cage  7  for enhanced durability, but it should not be such as to significantly increase the stiffness of the cage  7 .  
         [0031]      FIG. 2  shows the outer surface of the outer cage  7  which has a peripheral flange  10  defining a central space  11  and a plurality of bars  12  extending arcuately over the central space  11  from the inner edge  13  of the peripheral flange  10  to form the structure of the cage  7 . The degree of arc of the bars  12  is sufficient to create a concave space within which to receive the inner perforated dome  8  and, when worn by the user, the outer auricle of the ear.  
         [0032]     In plan view, cage  7  has a substantially pentagonal shape defined by five lobes  14 . Four lobes  14  are provided with slots  15  for passage of the head straps  4 , while the fifth lobe  14  is provided with a snap  16  or other releasable fastener for the chin strap  5 . The bars  12  forming the arcuate cage structure over the central space  11  extend from the inner edge  13  of the peripheral flange at each of the lobes  14  and form the outermost surface of the ear protectors  2  and  3 . Force exerted against the bars  12  is absorbed by the bars  12  and is directed outward along the bars  12  to the peripheral flange  10 .  
         [0033]      FIG. 3  shows the inner surface of the cage  7 . To accommodate the inner perforated dome  8  when the ear protectors  2  and  3  are assembled, the inner surface of the peripheral flange  10  is molded with a relieved area  17  surrounding the inner edge  13  of the flange  10  and extending into each of the four lobes  14  having slots  15  in the shape of a tab  18  encompassing the slots  15 . At the fifth lobe behind the location of snap  16  on the outer surface of the peripheral flange  10  is provided a releasable fastener  19 , such as Velcro®, double stick tape, or the like, for releasably affixing the peripheral resilient pad  9  as will be described later.  
         [0034]     Relieved area  17  corresponds to a second peripheral flange  21  on the inner perforated dome  8 . Spaced around the relieved area  17  and along the underside of bars  12  are a plurality of locating pins  20  which correspond to locating holes  22  formed in the second flange  21  and central cup  23  of the perforated dome  8 . Locating pins may be formed with an annular ring or lip at their outer ends to provide a detent for a secure snap fit of locating pins  20  into locating holes  22  when the outer cage  7  and perforated dome  8  are assembled.  
         [0035]     Inner perforated dome  8  is illustrated in  FIG. 4  and includes a central cup  23  surrounded by a peripheral flange  21 . Central cup  23  provides a concave inner space to fit over the user&#39;s ear and itself fits within the corresponding concave space formed by the arcuate bars  12  of outer cage  7 . Like cage  7 , dome  8  has a substantially pentagonal shape with peripheral flange  21  corresponding to the relieved area  17  on the underside of the peripheral flange  10  of cage  7  so as to fit in and be received by relieved area  17  when cage  7  and dome  8  are assembled. Tabs  24  at four of the corners of peripheral flange  21  correspond to the tab shapes  18  of the relieved area  17  and have slots  25  corresponding to and aligned with slots  15  for passage of the head straps  4  when the cage  7  and dome  8  are assembled.  
         [0036]     To provide strength and resistance to crushing while maintaining a degree of resiliency, perforated dome  8  is preferably molded with a plurality of ribs  26  in central cup  23 . Ribs  26  correspond in shape and location to the arcuate bars  12  of cage  7  and, in so doing, assist in the direction of forces of shock and compression over the surface of central cup  23  and outward to the peripheral flanges  10  and  21 . As shown in  FIG. 4 , additional or secondary ribs  27  may be included in central cup  23 .  
         [0037]     In order to provide air flow and pressure relief to the user&#39;s ears, dome  8  is provided with a plurality of perforations  28  in the central cup  23  in the spaces between the ribs  26  and secondary ribs  27 . The perforations  28  may take any shape but their location and formation should not interfere with ribs  26  or secondary ribs  27 .  
         [0038]     It has been found that by distributing the perforations  28  substantially evenly over the central cup  23  improved ventilation of the ear is achieved together with improved hearing by the user over other ear protectors having a limited number of ventilation holes located substantially centrally over the ear. In addition, with the wide and even dispersal of the perforations  28  over the whole area of the central cup  23 , it is virtually impossible to completely block all of them thus significantly reducing the likelihood of a user suffering damage to the ear drum or ear canal due to a sudden pressure increase within the ear protector caused by a direct blow.  
         [0039]     Spaced around the peripheral flange  21  and along ribs  26  are locating holes  22  which correspond to locating pins  20  previously described on outer cage  7 . Locating holes  22  receive locating pins  20  when the cage  7  and dome  8  are assembled and, together with the fitting of flange  21  in relieved area  17 , serve to ensure proper registration of cage  7  and dome  8 . In addition, pins  20  and holes  22  serve to help prevent any relative displacement of cage  7  and dome  8  during use.  
         [0040]     Like the outer cage  7 , inner perforated dome  8  is molded from a reinforced or non-reinforced polymer such as polyurethane, polyvinyl chloride, hytrel, thermoplastic urethane, or the like. However, the durometer is higher than that of the cage  7 , on the order of 90-100 or, preferably, 90-95. Preferably the polymer used is a non-reinforced PVC or TPU.  
         [0041]     The third element of the ear protectors  2  and  3  is the peripheral resilient pad  9  which is made from a resilient foam, preferably a closed cell foam of moderate density, most preferably EVA foam having a density of from 0.05 to 1.0 g/cm 3  and a thickness of from 1 to 2 centimeters. Although closed cell EVA foam is preferred, other open or closed cell foams may be used such as ensolite, polyethylene, polyurethane and irradiated cross-linked polyethylene. Preferably, the surface of pad  9  has a smooth, low friction surface for strength and comfort. This may be a skin formed on the foam surface during the molding operation or by dipping the finished foam pad in liquid vinyl. Alternatively, a thin, lightweight woven or non-woven fabric cover, such as tricot or Lycra® may be applied.  
         [0042]     In its simplest form, peripheral resilient pad  9  substantially conforms to the size and shape of the peripheral flange  10  of cage  7  as shown in  FIGS. 6 and 7  and includes slots  29  corresponding to and aligning with slots  15  of cage  7  and slots  25  of dome  8 . Head straps  4  pass through all three sets of slots to hold the three elements together as shown in  FIG. 1 . A central space  30  provides passage of the user&#39;s outer ear into the central cup  23  of perforated dome  8 . In addition, a releasable fastener  31  which is co-operable with releasable fastener  19  on the cage flange  10  is located on the comparable lobe  33  of pad  9 . Thus, when pad  9  is placed against the inner surface of flange  10 , releasable fasteners  19  and  31  co-operate to hold the fifth lobe of pad  9  in place against the fifth lobe of flange  10  while the head straps  4  hold the other four lobes in place. In addition, pad  9  presses against flange  21  of dome  8  to aid in its retention within relieved area  17 .  
         [0043]     In a more preferred form, peripheral resilient pad  9  is slightly larger than the peripheral flange  10  of cage  7  so as to overlap the outer and inner edges of flange  10  thereby providing additional protection.  
         [0044]     A particularly preferred embodiment of peripheral resilient pad  9  is shown in  FIGS. 6 and 7 . In this embodiment, the underside of pad  9  to fit against the side of a user&#39;s head and shown in  FIG. 6 , is provided with air relief channels  32  extending from central space  30  to the outer edge of pad  9 . In addition, strap lobes  33  each have a recessed strap channel  34  molded into the foam from the slot  29  to the outer edge of the lobe  33  such that head straps  4  are recessed and less likely to irritate the wearer.  
         [0045]      FIG. 7  illustrates the upper surface of the preferred embodiment of pad  9  showing a raised perimeter bead  35  that engages around and cushions the outer edge of peripheral flange  10  of cage  7 . For added protection and to further hold pad  9  in place the raised perimeter bead  35  may also have an undercut, thereby forming a recess under the bead  35  to hold the outer edge of flange  10  and permit the bead  35  to roll over the edge of flange  10  as shown in  FIG. 8 .  
         [0046]     The above described construction for ear protectors  2  and  3  provides greater protection for users and the added advantages of being easily disassembled for repair or replacement of parts and meeting the requirements of international wrestling rules.  
         [0047]     The structure of the ear protectors provides several levels of shock absorbance. When in use, first contact with the ear protectors is in the bars  12  of the outer cage  7  which, because of their construction and the durometer of the material thereof, undergo a slight compression against the inner perforated dome  8 . Simultaneously, the resistance of the dome  8  cause the force of such contact to be directed along the bars  12  to the flange  10  for absorbance by the peripheral foam pad  9 .  
         [0048]     In the event a sudden shock is applied to the outer surface of the ear protectors  2  and  3 , not only is a portion of that shock absorbed and redirected by the structure of the ear protectors  2  and  3  as described above, but, where the force of the shock is sufficient, the central cup  23  of perforated dome  8  will flex also absorbing and directing the shock radially outward along ribs  26  and secondary ribs  27 . In this manner, less of the shock and associated pressure is transmitted to the user&#39;s ears.  
         [0049]     Furthermore, with ventilation provided over substantially the entire area of the central cup  23  of dome  8  and with the bars  12  of cage  7  providing a raised contact surface above the perforations  28 , injury as a result of sudden increases in air pressure within the ear protectors due to inadvertent blockage of the air holes common to other ear guards and ear protectors is eliminated.  
         [0050]     The structure of the ear protectors and the resulting headgear has added benefits in that it permits the individual elements of the headgear to be manufactured and assembled in a plurality of colors and combinations to match those of national, regional and/or local teams and for completed headgear to be easily customized to a user&#39;s preferences. Furthermore, users may easily disassemble the headgear and era protectors for repair and/or replacement of any of the different elements as needed.  
         [0051]     While the invention has been described with respect to certain specific embodiments, it will be appreciated that many modifications and changes may be made by those skilled in the art without departing from the spirit of the invention. It is intended, therefore, by the appended claims to cover all such modifications and changes as fall within the true spirit and scope of the invention.