Patent Publication Number: US-2015059055-A1

Title: Disposable absorbent insert for an athletic head covering

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation-in-part of U.S. patent application Ser. No. 13/709,913, filed on Dec. 10, 2012, titled DISPOSABLE ABSORBENT INSERT FOR AN ATHLETIC HEAD COVERING, which claims the benefit of U.S. patent application Ser. No. 12/416,529, filed on Apr. 1, 2009, titled DISPOSABLE ABSORBENT INSERT FOR AN ATHLETIC HEAD COVERING, which claims the benefit of U.S. Provisional Application No. 61/041,388, filed on Apr. 1, 2008, titled DISPOSABLE ABSORBENT INSERT FOR AN ATHLETIC HEAD COVERING. 
    
    
     FIELD OF THE DISCLOSURE 
     The disclosed invention relates to a device for absorbing and retaining sweat. More specifically, it relates to a wearable, adhesive, disposable device that a user can insert into a hat or helmet to prevent sweat from dripping onto the user&#39;s face. 
     BACKGROUND OF THE INVENTION 
     Sports have been a form of hobby, community involvement and source of exercise for people for decades. The athletic equipment industry is stable and is one that is becoming more and more technologically advanced. Athletes are constantly looking for new ways to enhance their performance and gain a competitive edge over their opponents. 
     A common problem that many athletes experience is sweat dripping from their foreheads into their eyes. Inhibiting sweat or any type of moisture from dripping down into the eyes, nose, mouth and other areas of the athlete&#39;s face will allow the athlete to concentrate on the game being played and not be distracted or uncomfortable during his or her athletic performance. The use of an insert enhances the performance of an athlete during activity by mitigating the possibility of sweat and oil dripping down onto the athlete&#39;s face during activity and impairing his or her vision. 
     Currently, there are a variety of moisture absorbing devices for absorbing sweat and other moisture away from the head of an individual during various activities. Such absorbent devices have been used as an insert in a cap, hat, hardhat or sun visor. However, a problem with many inserts is that they are difficult to clean and are not easily replaced when soiled or saturated. Moreover, many disposable inserts are not well shaped for the contours of athletic headwear. 
     SUMMARY OF THE INVENTION 
     In one aspect, a disposable absorbent insert for fitting against a forehead-contacting, curved inside surface of a user&#39;s athletic head covering comprises a moisture wicking layer; a liquid absorbent core layer; a liquid impervious layer; an adhesive layer comprising a repositionable pressure-sensitive adhesive; and a release liner layer. A top edge of the insert comprises a plurality of slits to facilitate fitting of the insert onto the curved inside surface of the athletic head covering. 
     In another aspect, a method of using a disposable absorbent insert on a forehead-contacting, curved inside surface of a user&#39;s athletic head covering is described. The insert comprises a liquid absorbent layer, an adhesive layer, and a release liner layer, wherein a top edge of the insert comprises a plurality of slits. The method comprises separating the release liner layer from the adhesive layer and contacting the adhesive layer to the curved inside surface of the athletic head covering while manipulating the top edge of the insert via the slits to fit the insert onto the curved inside surface of the athletic head covering without overlapping areas of the insert. 
     This Summary is provided to introduce concepts in simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the disclosed or claimed subject matter, and is not intended to describe each disclosed embodiment or every implementation of the disclosed or claimed subject matter, and is not intended to be used as an aid in determining the scope of the claimed subject matter. Many other novel advantages, features, and relationships will become apparent as this description proceeds. The figures and the description that follow more particularly exemplify illustrative embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a top-down view of one embodiment of the disclosed insert. 
         FIG. 2  is a side view of an athletic helmet with the insert of  FIG. 1  positioned inside the front portion of the helmet. 
         FIG. 3  is a front view of the helmet of  FIG. 2 . 
         FIG. 4  is a partial sectional view of the disclosed insert, taken along line  4 - 4  of  FIG. 1 . 
         FIG. 5  is a top-down view of one embodiment of the disclosed insert. 
         FIG. 6  is a partial sectional view o f one embodiment of the disclosed insert, taken along lines  4 - 4  of  FIG. 1 . 
         FIG. 7  is an exploded view of one embodiment of the disclosed insert. 
         FIG. 8  is a perspective view of one embodiment of the disclosed insert. 
         FIG. 9  is a perspective view of one embodiment of the disclosed insert. 
         FIG. 10  is a right side perspective view of one embodiment of the disclosed insert. 
         FIG. 11  is a right side view of one embodiment of the disclosed insert. 
         FIG. 12  is a front view of one embodiment of the disclosed insert. 
         FIG. 13  is a top-down view of one embodiment of the disclosed insert. 
         FIG. 14  is a back perspective view of one embodiment of the disclosed insert. 
         FIG. 15  is a top-down view of one embodiment of the disclosed insert. 
         FIG. 16  is a top-down view of the top layer of one embodiment of the disclosed insert. 
         FIG. 17  is a top-down view of the adhesive layer of one embodiment of the disclosed insert. 
     
    
    
     DETAILED DESCRIPTION 
     Various user interfaces and embodiments will be described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Reference to various embodiments does not limit the scope of the claims attached hereto. Additionally, any examples set forth in this specification are not intended to be limiting and merely set forth some of the many possible embodiments for the appended claims. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but these are intended to cover application or embodiments without departing from the spirit or scope of the claims attached hereto. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. 
     One embodiment of this disclosure relates to a disposable insert that wicks moisture away from the athlete&#39;s forehead. The insert can be a disposable, moisture-absorbing device that is affixed to a head covering, such as a helmet or hat, specifically athletic head coverings used in sports, which include but are not limited to baseball, football, hockey, and lacrosse. Alternatively, the insert can attach itself to a user&#39;s head using other means that do not require a head covering. The disposable, absorbent insert is specifically designed to fit within the aforementioned athletic head coverings and other related contact sport head covering. In one embodiment, the material from which the disposable insert is comprised is not elastic. In another embodiment, at least some of the material from which the disposable insert is comprised is elastic. For example, the absorbent portion of the insert can be made from a non-elastic material, whereas the fabric that covers the absorbent part can be made from elastic material. In another example, both the absorbent portions and the fabric cover can be made from, or include, elastic material. In some embodiments, the insert is made using materials similarly used in the making of feminine hygiene pads. The insert can, in some embodiments, be recyclable or made of biodegradable materials. Additionally, the materials used in the insert can be breathable so the insert does not block ventilation from the head covering. 
     The disposable absorbent insert can be adhered to the curved inside surface of the athletic head covering. The insert can be easily attached to the athletic head covering immediately before athletic activity and can then be removed from the athletic head covering and discarded after physical activity has ceased. In addition, a soiled insert may be replaced with a fresh insert during athletic activities (e.g., during a timeout, between periods, at halftime, etc.). 
     The disposable absorbent insert of this disclosure is a new form of technology that has not previously been available to the athletic equipment industry. As mentioned above, athletes are always looking for a competitive edge and are willing to pay for it. The beauty of the disposable absorbent insert is that it is inexpensive to produce and thus will be inexpensive to purchase. As athletics evolve, more and more people are beginning to stick with one sport and play it all year round. These athletes generally are the people looking for the competitive edge and will most likely be frequent purchasers of the inserts (which may be sold and packaged individually or in packs of, for example, 10-12 inserts per pack). 
     A disposable absorbent insert for an athletic head covering is disclosed, as shown in  FIGS. 1-3 .  FIG. 1  is a view of an insert  10  laying flat.  FIG. 2  is a side view of an athletic helmet (e.g., a hockey helmet), illustrating the orientation of the insert  10  within the helmet  20 , from the side.  FIG. 3  is a front view of the helmet  20  of  FIG. 2 , illustrating the orientation of the insert within the helmet.  FIGS. 4 and 6  are partial sectional views of the insert  10 , such as taken along lines  4 - 4  in  FIG. 1 .  FIG. 7  is an exploded view of the layers of the insert  10 . 
     This disposable absorbent insert can, in one embodiment, be fitted against the inside surface of an athletic helmet. The insert, when placed on the front portion of the helmet or hat, functions to wick moisture away from the head of the athlete and prevent moisture from dripping down into the eyes, nose, mouth and overall facial area of an athlete. If placed at the back of a helmet or hat, it can also prevent moisture from dripping down onto the neck of an athlete. The insert can be in direct contact with the athlete&#39;s forehead and can be formed of an absorbent material. In one embodiment, as illustrated in  FIGS. 4 ,  6  and  7 , the insert is comprised of several layers. These layers function to wick moisture away from the athlete&#39;s forehead, trap moisture inside the disposable insert and prevent moisture from dripping down onto the face of an athlete. 
     The disposable absorbent insert can benefit its user in many ways. The most apparent benefit is keeping sweat originating on an athlete&#39;s forehead and hair from dripping down onto the athlete&#39;s face or neck. When perspiration drips down onto an athlete&#39;s face it can impair the athlete&#39;s vision, which can be a painful annoyance and disrupt the play and overall performance of the athlete during the run of play. 
     In some sports (e.g., hockey), many players use glass/plastic facial shields, which have a high tendency to fog up during use as perspiration and moisture enter into the area between the athlete&#39;s face and the shield. The disposable insert of this disclosure can help its user by eliminating almost all perspiration from dripping down onto the athlete&#39;s face. This will greatly decrease the probability of the glass/plastic facial shield fogging up and will not impair the athlete&#39;s vision during the run of play. Additionally, athletic head coverings are usually unable to be thoroughly washed and, therefore, they lock moisture, oils, and odors in. Use of the insert enables the sweat, oils, and odors to get locked in the insert and, therefore, reduces scents odors from accumulating in the head covering. 
     Skin hygiene is another important benefit from using the insert. Many adult and teenage athletes who wear helmets during their sporting activities experience increased skin irritation and facial acne while in season. Sweat and oil from the athlete&#39;s hair and forehead can drip down onto the face, which can plug up facial pores and cause the unwanted facial blemishes. Also, the pressure and direct contact that an athlete&#39;s forehead has with the helmet can cause skin rashes and increased acne as well. The disposable insert will prevent sweat and oil from dripping down onto the face and clogging the athlete&#39;s facial pores. The soft material of which the disposable insert is made will provide a comfortable barrier between the athlete&#39;s forehead and helmet and will eliminate skin irritation and blemishes caused by the friction between the forehead and the inside surface of the helmet. In some embodiments, the insert may contain acne cream, other acne topicals, or an antibacterial or antimicrobial. The insert could also contain lotion, aloe, vitamins, pharmaceuticals, or bug spray and can be hypoallergenic, latex free, or both. 
     In one exemplary embodiment, the disposable insert can be made by a manufacturer in dimensions of: Length L: 180 mm to 330 mm (e.g., length=250 mm); Width W: about 100 mm (e.g., width=97 mm); Thickness T: about 2 mm to about 10 mm (or even thinner, from about 2-7 mm (e.g., thickness=4-5 mm)). 
     In one embodiment, each insert is generally uniform in thickness and has a lower curved edge  22  and rounded end edges  24  and  26 . Each insert  10  has a top edge  28 , which is interrupted by one or more slits  30  or gaps, which are cut through all layers of the insert and angled towards a central portion of the insert. In the illustrative embodiment, two slits  30   a  and  30   b  are provided, and they are angled inwardly toward a central portion  31  of insert  10 . Slits  30   a  and  30   b  allow insert  10  to naturally follow the contours of the inside curved surface of helmet  20 . Moreover, such angling of slits  30   a,    30   b  allows the slits to lie naturally along helmet  20  contour lines, such as front-to-back lines shown in  FIG. 2 . Accordingly, the gaps caused by slits  30   a,    30   b  are least obtrusive to the user. The top edge  28  is thus divided into top edge portions  28   a,    28   b  and  28   c.  Top edges  28   a  and  28   c  are generally curved, while top edge  28   b  is generally linear. 
     One embodiment of a disposable insert  110  is illustrated in  FIG. 5 , in a top-down view. This embodiment has a slightly different configuration from that illustrated in  FIG. 1 , with top edges  128   a,    128   b  and  128   c  having collinear sections thereon, and with lower edge  122  having linear sections  122   a  and  122   b  between its center (about a center line C) and rounded end edges  124  and  126 , respectively, of the insert  110 . In one embodiment, a length L1 of the insert  110  is about 248 mm and a width W1 of the insert  110  is about 90 mm. The insert  110  is asymmetrical about the centerline C. 
     The insert  10 ,  110  may be multilayer in construction. The top layer  702 , illustrated in  FIGS. 1 ,  5 , and  16 , contacts the athlete, is moisture absorbent, and may have a moisture- wicking functional attribute to draw sweat away from the athlete. It can allow moisture to pass through in one direction from the user&#39;s skin surface into the core of the product. An inner layer, or core, is also moisture absorbent and may have moisture retention attributes. 
     The core may be formed from one layer of moisture absorbent/retentive material, as illustrated in  FIG. 4 , or two or more layers of such material, as illustrated in  FIG. 6 . These moisture absorbent/retentive layers form the core of the insert and may be formed from non-woven materials including, for example, non-woven wood, wood pulp fibers, paper or non- woven absorbent polymeric fibers, or the like. 
     For instance, in one example, the core includes two layers that are moisture absorbent/retentive layers. The first layer can be made of a perforated non-woven material (e.g., spunlace) material, and the second layer can be an absorbent paper. 
     In another embodiment, as illustrated in  FIG. 7 , the core can contain three layers, wherein the first layer is a first airlaid layer  704 , the second layer is a super absorbent polymer (SAP) layer  706 , and the third layer is a second airlaid layer  708 . A moisture-barrier layer  710  may also be provided (e.g., a polyethylene film). For example, the type of materials used for feminine hygiene pads may suffice. Therefore, the insert, in a preferred embodiment, has a top, moisture wicking layer  702 , an absorbent core comprised of two airlaid layers  704 ,  708  that sandwich a SAP layer  706 , and a moisture barrier layer  710 . In another embodiment, a fifth, adhesive layer can attach to the moisture barrier layer. In this embodiment, the user can attach the disposable insert to a helmet or hat. The adhesive layer can be two-sided tape, wherein one side faces the moisture-barrier layer and the other side faces a sixth layer that is a release liner that is removed before use. The adhesive layer can be a full coverage adhesive layer, wherein it covers the entire surface of the moisture barrier layer  710 , or it can be a partial coverage adhesive layer  1702 , wherein it covers only a portion of the moisture barrier layer  710 , as illustrated in  FIG. 17 . 
     In some embodiments, a sealed perimeter  1502  can be made when the perimeter of at least the top layer, core layers, and moisture barrier layer are sealed together, as illustrated in  FIG. 15 . The seal can be made using means such as, but not limited to, construction glue and pressure, ultrasonic weld/seal, or heat and pressure. Sealing these layers together enables moisture to be locked in the core. 
     In some embodiments, an impermeable gutter layer may also be included in the insert, wherein the impermeable gutter layer is located along the bottom edge and acts to pick up excess sweat that the core cannot contain. 
     The disposable absorbent insert can be fitted against the inside surface of an athletic head covering, as illustrated in  FIGS. 2 and 3 . The insert can also be fitted against the inside back surface of an athletic head covering. In an alternative embodiment, the disposable insert can be a band, such as, but not limited to, a headband, wristband, or sweatband, and it can be positioned around a user&#39;s head without the need to be adhered to a helmet or hat. For example, the disposable insert can be an entirely elastic band, as illustrated in  FIGS. 8 and 9 . In another example, the disposable insert can be a band that is tied onto a user&#39;s head, as illustrated in  FIGS. 10-12 . In this example, the band can be comprised of an absorbent portion  1002  and a tie portion  1004  so that the user can tie the band as tight as he or she wishes. In another example, the disposable insert can be a band that has at least some portion that is an elastic band  1304  and an absorbent portion  1302 , as illustrated in  FIGS. 13 and 14 . The insert functions to wick moisture away from the head of the athlete and prevent moisture from dripping down into the eyes, nose, mouth and overall facial area of the athlete. The insert will be in direct contact with the athlete&#39;s head and hair. 
     The insert  10 ,  110  is formed of an absorbent material and can be comprised of several layers, as illustrated in  FIGS. 4 ,  6 , and  7 . In one embodiment, the insert  10 ,  110  is comprised of a top-sheet layer  35  that wicks moisture away from the athlete&#39;s head. On a bottom-side of the top-sheet layer  35 , is an absorbent core layer  37  that collects and holds the moisture that has been wicked away from the athlete&#39;s head. On a bottom-side of the absorbent core layer  37  is a water impervious bottom-sheet layer  39  that, along with the top-sheet layer  35 , encases the absorbent core layer  37  and prohibits moisture from leaving the absorbent core layer  37 . 
     On a bottom-side of the bottom-sheet layer  39  is a pressure sensitive adhesive layer  41  covering, in one embodiment, the entire span of a bottom-side of the bottom-sheet layer  39 . In another embodiment, only part of the bottom-side of the bottom-sheet layer  39  is covered by the pressure sensitive adhesive layer  41 . This will allow the insert  10 ,  110  to adhere to the surface on the inside of the athletic head covering  20 . The adhesive of layer  41  is repositionable pressure sensitive adhesive (and may take the form of double-sided tape), which allows insert  10 ,  110  to be removed and discarded from a helmet (or helmet liner) without leaving adhesive residue. A removable release liner layer  43  covers the adhesive layer  41  prior to use and is removed to expose the adhesive layer  41  for mounting the insert  10 ,  110  within the helmet  20 . In one embodiment, the release liner layer  43  is release paper. 
     In an alternative embodiment, as seen in  FIG. 6 , the insert  10 ,  110  is comprised of a top- sheet layer  135  that wicks moisture away from the athlete&#39;s head. Below the top-sheet layer, an absorbent core layer  137  is comprised of a first absorbent layer  137   a  and a second absorbent layer  137   b.  The absorbent core layer  137  collects and holds the moisture that has been wicked away from the athlete&#39;s head. Underneath the absorbent core layer  137  is a water impervious bottom-sheet layer  139  that, along with the top-sheet layer  135 , encases the absorbent core layer  137  and prohibits moisture from leaving the absorbent core layer  137 . 
     On a bottom-side of the bottom-sheet layer  139  is a pressure-sensitive adhesive layer  141  covering, in one embodiment, the entire span of a bottom-side of the bottom-sheet layer  139 . This will allow the insert  10 ,  110  to adhere to the surface on the inside of the athletic head covering  20 . The adhesive of layer  141  is repositionable pressure sensitive adhesive (and may take the form of double-sided tape), which allows insert  10 ,  110  to be removed and discarded from a helmet (or helmet liner) without leaving adhesive residue. A removable release liner layer  143  covers the adhesive layer  141  prior to use and is removed to expose the adhesive layer  141  for mounting the insert  10 ,  110  within the helmet  20 . In one embodiment, the release liner layer  143  is made of release paper. 
     In some embodiments, the moisture wicking layer, the moisture barrier layer, or both can incorporate flame-resistant fibers (e.g., Nomex by DuPont). In some embodiments, the insert can include an absorption or saturation indicator, such as a color change indicator, wherein the color changes as more sweat is absorbed, and the change in color enables the user to know how much sweat the insert has absorbed and about how much more it can absorb. In some embodiments, the absorption or saturation indicator can be a strip on the insert. In one embodiment, the insert can include glow in the dark materials so that the insert is visible in darkness. 
     In order to use the insert  10 ,  110 , the removable release liner layer  43  is removed from the adhesive layer  41  by peeling it from the adhesive layer  41 . Insert  10 ,  110  is then applied to the helmet  20 , either applying it directly to interior surfaces of the helmet shell itself, or to a helmet liner shaped to conform to a user&#39;s head. The repositionable pressure sensitive adhesive of the adhesive layer  41  holds the insert  10 ,  110  in place. The grooves  30  in the insert  10 ,  110  facilitate that bending of the insert  10 ,  110  to conform to the shape of the helmet  20 , as illustrated in  FIG. 2 , and to prevent overlapping of the material of the insert  10 ,  110 . By preventing such overlap, a smooth surface of insert  10 ,  110  lies against the user&#39;s head for increased comfort. After installation, the insert  10 ,  110  is firmly secured to the helmet  20  by the repositionable pressure sensitive adhesive, with the exposed surface of the insert  10 ,  110  forming a head and temple contacting surface for the wearer of the helmet  20 . After use, the insert is easily removed by breaking the adhesive seal between the insert and the curved inside surface of the athletic helmet  20 . 
     In one embodiment, the insert may be an absorbent cylinder that can be elastic. The cylinder can include three layers: a top layer, an airlaid layer, and a SAP layer. The SAP layer can be in the middle of the cylinder and the layers can be rolled up like a tube. In one embodiment, several cylinders or tubes can be intertwined or braided together to make a larger end product. 
     Although the disposable absorbent insert for an athletic head covering disclosed herein has been described with respect to several embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the disclosure.